Hello flynny,
You need to find the old Sent Items.dbx file, and copy it to a safe place. Then use a utility to extract emails from dbx file one at a time. Then drag the extracted files to the Preview Pane in Outlook Express.
The following utilities will do the above extraction:
Macallan <-- free
http://insideoe.tomsterdam.com/resources/tools.htm#macallanOR
DBXtract <-- low cost
http://www.pcworld.com/downloads/file/fid,23383-order,1-page,1/description.htmlOR
Outlook Express Repair Tool <-- free 30 trial version
http://www.nsware.com/Repair-Tool-for-Outlook-Express.htmHope this helps!
war1