4 min IOKit boot hang on Unibody Mac 10.5.7 - failure of Hard Drive?

I am experiencing a boot hang of 4 minutes (4 minutes of 0 activity) on the blue screen part of the boot process in OS 10.5.7. This hang happens on every boot.
Inspecting the disk (with Disk Verify in Disk Util) revealed errors (incorrect volume file count) I am in Italy on a work placement and my install disks are in the UK (I know, I'm an idiot...) so, on advice from the support site, I booted into single user mode to fix the issue with fsck -yf. This repaired that issue, however I am still experiencing the same boot time hang.
Here are the relevant sections of the system log:
Jun 11 21:07:11 Aquaria configd38: setting hostname to "Aquaria.local"
Jun 11 21:07:11 Aquaria /usr/sbin/ocspd63: starting
Jun 11 21:07:12 Aquaria mDNSResponder mDNSResponder-176.3 (Sep 30 2008 16:59:38)25: starting
Jun 11 21:07:12 Aquaria com.apple.usbmuxd16: usbmuxd-167 built for iTunesEightTwo on May 11 2009 at 13:36:48, running 32 bit
Jun 11 21:07:14 Aquaria kernel[0]: Auth result for: 00:80:5a:47:80:fb MAC AUTH succeeded
Jun 11 21:07:14 Aquaria kernel[0]: AirPort: Link Up on en1
Jun 11 21:07:14 Aquaria fseventsd31: log dir: /Volumes/RAPTOR/.fseventsd getting new uuid: CA0E7CFE-8A99-466A-AAB8-CEB992565E4C
Jun 11 19:07:32 Aquaria kextd10: IOKitWaitQuiet() timed out waiting to write kernel symbols
Jun 11 19:07:42 Aquaria kextd10: writing kernel link data to /var/run/mach.sym
Jun 11 19:08:06 Aquaria configd38: InterfaceNamer: timed out waiting for IOKit to quiesce
Jun 11 19:08:06 Aquaria configd38: InterfaceNamer: Busy services :
Jun 11 19:08:06 Aquaria configd38: InterfaceNamer: MacBook5,1 [1]
Jun 11 19:08:06 Aquaria configd38: InterfaceNamer: MacBook5,1/AppleACPIPlatformExpert [1]
Jun 11 19:08:06 Aquaria configd38: InterfaceNamer: MacBook5,1/AppleACPIPlatformExpert/PCI0@0 [1]
Jun 11 19:08:06 Aquaria configd38: InterfaceNamer: MacBook5,1/AppleACPIPlatformExpert/PCI0@0/AppleACPIPCI [1]
Jun 11 19:08:06 Aquaria configd38: InterfaceNamer: MacBook5,1/AppleACPIPlatformExpert/PCI0@0/AppleACPIPCI/SATA@B [1]
Jun 11 19:08:06 Aquaria configd38: InterfaceNamer: MacBook5,1/AppleACPIPlatformExpert/PCI0@0/AppleACPIPCI/SATA@B/AppleMCP79AHCI [1]
Jun 11 19:08:06 Aquaria configd38: InterfaceNamer: MacBook5,1/AppleACPIPlatformExpert/PCI0@0/AppleACPIPCI/SATA@B/AppleMCP79AHCI/PR T1@1 [1]
Jun 11 19:08:06 Aquaria configd38: InterfaceNamer: MacBook5,1/AppleACPIPlatformExpert/PCI0@0/AppleACPIPCI/SATA@B/AppleMCP79AHCI/PR T1@1/IOAHCIDevice@0 [1]
Jun 11 19:08:06 Aquaria configd38: InterfaceNamer: MacBook5,1/AppleACPIPlatformExpert/PCI0@0/AppleACPIPCI/SATA@B/AppleMCP79AHCI/PR T1@1/IOAHCIDevice@0/IOAHCISerialATAPI [1]
Jun 11 19:08:06 Aquaria configd38: InterfaceNamer: MacBook5,1/AppleACPIPlatformExpert/PCI0@0/AppleACPIPCI/SATA@B/AppleMCP79AHCI/PR T1@1/IOAHCIDevice@0/IOAHCISerialATAPI/IOSCSIPeripheralDeviceNub [1]
Jun 11 19:12:12 Aquaria /usr/libexec/hidd30: Timeout waiting for IOKit to be quiet
Jun 11 19:12:12 Aquaria /usr/libexec/hidd30: IOHIDEventQueueCreate: Unable to allocate queue memory from IOHIDSystem. (0x10000003)
Jun 11 19:12:12 Aquaria WindowServer60: Unable to create event queue via hidd: (0xe00002bd)
Jun 11 19:12:18 Aquaria loginwindow26: Login Window Started Security Agent
Jun 11 19:12:19 Aquaria mds24: (/Volumes/Cloud 9/.Spotlight-V100/Store-V1/Stores/86FD4288-4FB4-4E9C-BBD4-2D265B8E6068)(Error) IndexCI in ContentIndexOpenBulk:Could not open /Volumes/Cloud 9/.Spotlight-V100/Store-V1/Stores/86FD4288-4FB4-4E9C-BBD4-2D265B8E6068/live.2.; needs recovery
Jun 11 19:12:19 Aquaria mds24: (/Volumes/Cloud 9/.Spotlight-V100/Store-V1/Stores/86FD4288-4FB4-4E9C-BBD4-2D265B8E6068)(Error) IndexStore in SIStoreDirytySDBChunks:Error storing dirty sdb pages: 30
Jun 11 19:12:19 Aquaria mds24: (/Volumes/Pegasus/.Spotlight-V100/Store-V1/Stores/0374BFCD-7DC1-48F2-B6CC-E5129 AEB5C81)(Error) IndexCI in ContentIndexOpenBulk:Could not open /Volumes/Pegasus/.Spotlight-V100/Store-V1/Stores/0374BFCD-7DC1-48F2-B6CC-E5129A EB5C81/live.0.; needs recovery
Jun 11 19:12:19 Aquaria mds24: (/Volumes/Pegasus/.Spotlight-V100/Store-V1/Stores/E7AC0B31-F344-489C-A95E-C7C32 6C63455)(Error) IndexCI in ContentIndexOpenBulk:Could not open /Volumes/Pegasus/.Spotlight-V100/Store-V1/Stores/E7AC0B31-F344-489C-A95E-C7C326 C63455/live.0.; needs recovery
Jun 11 19:12:19 Aquaria mds24: (/Volumes/Pegasus/.Spotlight-V100/Store-V1/Stores/0374BFCD-7DC1-48F2-B6CC-E5129 AEB5C81)(Error) IndexStore in SIStoreDirytySDBChunks:Error storing dirty sdb pages: 30
Jun 11 19:12:20 Aquaria mds24: (/Volumes/Pegasus/.Spotlight-V100/Store-V1/Stores/E7AC0B31-F344-489C-A95E-C7C32 6C63455)(Error) IndexStore in SIStoreDirytySDBChunks:Error storing dirty sdb pages: 30
Notice the hang between 19:08 and 19:12 of exactly 4 minutes, this is reproduced each boot. From what I understand the IOkit is timing out at 4 minutes while trying to do something with the SATA boot disk - is this correct.
Please advise as a way to resolve the problem - is it a hard drive in need or replacement or a driver issue which occured when I updated to 10.5.7 (could be cause - around the same time). The smart status of the drive is good but I am worried that I might be having hard drive issues and looking at a failure.
The problem and logs are also reproduceable when no external devices are plugged in.
Any help you can provide would be great I am panicking a little here! I have a backup but no Install disks!!
Mark

brainache151 wrote:
I am experiencing a boot hang of 4 minutes (4 minutes of 0 activity) on the blue screen part of the boot process in OS 10.5.7. This hang happens on every boot.
These threads
http://discussions.apple.com/thread.jspa?threadID=1470196
http://forums.macosxhints.com/archive/index.php/t-94723.html
suggest that you may have a hardware failure.

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