I think I'm running out of ideas - however, it occurs to me to ask:
This "tester" - do you mean a digital multimeter? ((Your reply implies a dedicated power loader. In which case you would not have the HDDs connected. The "tester" would go through a range of loadings and give you a time/performance log....I suspect this is not the case....))
+ Were these (now dead) HDD's acting as Slaves on yr sister's PC - Or did you install new OS and some working software...?
The disc-sizes are quite small, even for 4years old - do the discs have a date-stamp? (maybe ID from the chips, like 22-96 indicates week 22 of 1996 for example.). I wonder they are somewhat older than you say...?
Not sure this is going to be resolved, as several others (here) have tried also.
I'm wondering why you haven't replaced the PSU? - they are cheaper than HDDs - Surely with a decent HDD and new PSU the chances of another failure has to be very small - probably enough for an old PC.
If you want belt+braces, then maybe replace the mbd also, provided it will take the RAM and Video card. (it would be too much to expect it to take the old processor....). It sound extreme, but ...."family".......keep 'em happy.
Re grounding - yes, it's a possible source of trouble - those 4-pin power-connectors to HDDs (with IDE, I recall) were somewhat unreliable, but my experience was they just stopped the drive working (no power, no go!). I have only had HDD failure due to LT "wear-out" - ie there was no other culprit to blame.
I hope you've tried changing the ribbon connector leads...?
Is your sister sure no-one had done something to the old PC....what was her first "reported fault"?
I suspect it was the primary HDD
Finally I wonder if it was excess voltage that failed the drives? This might be from Storms, or local welding plant, even a badly supressed 1HP motor. It could affect the HDD, simply because that is operating at most-times, whereas the Optical is only on rarely.....in effect it avoids the spikes. Thse spikes would not show on a DMM but it's spikes that kill semiconductors.....like the motor controller. Fit a generous supressor, not one of those "Computer" types, I mean something with decent iron in the chokes.....My old win98SE pc has a PostOffice supressor on it, with a CVT in addition.....practically nothing can get through that. However, my Dell is straight on the mains....with nothing untoward.....I suppose I've softened my fears...and "here", there are no obvious spikes. Hope that helps.
Good Luck.