Can I recover mini hard drive?  1.66 core duo - fatal error w/ DU, AHT - OK

I had an internal hard drive issue after an interupted system update on 12/25 (two things were downloading, and I think it ran out of disk space). The mini (1.66 core due, 1 GB, superdrive, 10.4.?) would not restart, and had folder w/ a question mark. I could not find the drive w/ DU on the startup disk.
I was able to access the drive via firewire from my old G4 tower, and recovered all the data (using Prosoft Engineering's Data Rescue product - $99). The disk utility program on the G4 (OS 10.2.8) found no issues on the failed drive, and after I partitioned it and erased it with DU, the AHT on the mini install disk also found no issues.
The disk utility on the install disk says the drive has reported a "fatal hardware error to disk utility". I erased the drive via firewire on the G4, and was able to add 5 GB of photos to it and retrieve them w/ no issues - so the drive seems fine. Please help, I am very frustrated w/ Mac right now. I ordered a new mini (2.0 core duo from J&R, even w/ new mini announcement pending) to get moving again fast, but that one came on Jan 2nd with a faulty DVI port and has to be returned. I am now stuck on my old G4 only.
There were some useful posts I found - http://discussions.apple.com/thread.jspa?threadID=1528568&tstart=4
http://discussions.apple.com/thread.jspa?messageID=8340380&#8340380
But they don't fit exactly. On the format post, I don't have the "options" button available when I erase the failed HD (to fill it with all zeros). I've tried erasing it, but when I put the install disks in, it won't allow me to install to it.
Question: Is there any other way I might be able to install the OS onto my drive?
My fallback option is to buy a firewire external HD and just use that (maybe I can use my internal one as extra space, just not as a boot disk?
Thanks,
Chris

sooooo no one has any suggestions? 
My System Information:
Manufacturer & Model: HP Pavilion dv7 Notebook PC/NM101UA#ABA
Type of Computer: Laptop
CPU: Intel Mobile Core 2 Duo T6400 @ 2.00GHz 73 °C Penryn 45nm Technology
Motherboard: Hewlett-Packard 3624 (CPU) 69 °C
Mem: 4.00 GB Dual-Channel DDR2 @ 398MHz (6-6-6-18)
HDD: 244GB Seagate ST9250320AS ATA Device (SATA) 33 °C 244GB Seagate ST9250320AS ATA Device (SATA) 38 °C Video: Generic PnP Monitor (1600x900@60Hz) 1024MB ATI Mobility Radeon HD 4650 (HP)
Sound: High Definition Audio Device IDT High Definition Audio CODEC Bluetooth Hands-free Audio Bluetooth St
OS: MS Windows Vista Home Premium 64-bit SP1
Monitor: Generic PnP Monitor on ATI Mobility Radeon HD 4650 (1600x900 60Hz) ;work res(1600x870 60Hz)
ISP: Suddenlink

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