Can't open project unless trash prefs or eject ext hd... ???

I want to start off by apologizing ahead of time if I miss a detail or seem like I am rambling but I am going on 48 hours no sleep, half of which trying to figure out my problem, and my doc's air date is quickly quickly approaching. I will try to make this brief yet detailed...
I am working on a two hour documentary and I am having to hop between two machines.. one is at work and the other is at my home..
Home System:
MacBook Pro 10.5.8
2.66 GHz Intel Core 2 Duo 4 GB 1067 MHz DDR3
FCP 6.0.6
Work System:
2.5 GHz PowerPC Still on Tiger
FCP 6.0.6
(I apologize I don't know more details but I am at my home system right now and weary to drive up there on no sleep..)
I am editing XDCAM footage which I digitized in low res DV and then highres at the end to DVCPRO HD (since my system at work can't handle anything higher)
I have completed that entire process for the first hour of the doc with no issues.. having two copies of the SD version.. one at home and one at work and I would just throw my project file on a thumb drive and relink..
Ok.. so now I am trying to finish hour 2 and I've worked the exact same process as I did for hour 1.. This past Tuesday, it was at the end of the day and I just restarted my machine and tried to open my project and it would get stuck on the loading page... it did pass all the plugins loading... and would stop while it said ...6.0.6. Honestly I didn't think too much of it (panic wise) cause it's always something... lol.. I just did some quick googling... found that I should run permissions and trash my prefs.. Which I did.. and it opened just fine after that.
Rest of the week went fine until yesterday. At work again... it did the exact same thing. Now I am getting a bit concerned since I've never had to trash prefs before and now it's happening twice in one week...? hmmm.. Since works computer is still on Tiger, I can't download Digital Rebellion FCS Maintenance Pack.. (BUT I do have it on my home system..) So.. I went through the above process once again... and it opened just fine again.
brought my project file home last night and it was working just fine until around 2am and I couldn't open the darn project.. 'application not responding' force quit by control clicking on the dock...
Now that I am on my MPB, I decided to run the digital rebellion package (except the trashing of prefs..) Im trying to see if it's something else. I booted in Safe Mode and ran permissions there... restarted..... still can't open. So I ejected the media and it opened.. so now I have two ways to open it but it's the only way??? I even created a new project and copied my assets over to the new project (offline still)... and it still won't open.
I have to highres Monday and I am terrified to see what will happen ...
Others I tried:
-pulled all the plugins out of the plugin folder and it still wouldn't open..
-Ran Disk Warrior on both machines.. nothing major happened there.
Here is part of the report that is generated after the force quit to send to Apple:
Date/Time: 2010-02-20 10:56:55 -0700
OS Version: 10.5.8 (Build 9L30)
Architecture: i386
Report Version: 4
Command: Final Cut Pro
Path: /Applications/Final Cut Pro.app/Contents/MacOS/Final Cut Pro
Version: 6.0.6 (6.0.6)
Build Version: 12
Project Name: FCPApp
Source Version: 905291121
Parent: launchd [96]
PID: 381
Event: hang
Time: 5.08s
Steps: 27
Process: Final Cut Pro [381]
Path: /Applications/Final Cut Pro.app/Contents/MacOS/Final Cut Pro
ADDRESS BINARY
00001000 /Applications/Final Cut Pro.app/Contents/MacOS/Final Cut Pro
00b23000 /Applications/Final Cut Pro.app/Contents/MacOS/../Frameworks/KGCore.framework/Versions/A/KGCore
00b2d000 /System/Library/Frameworks/DVComponentGlue.framework/Versions/A/DVComponentGlue
00b32000 /Applications/Final Cut Pro.app/Contents/MacOS/../Frameworks/AERegistration.framework/Versions/A/AERegi stration
00b53000 /Applications/Final Cut Pro.app/Contents/MacOS/../Frameworks/AEProfiling.framework/Versions/A/AEProfili ng
00b62000 /System/Library/PrivateFrameworks/ProKit.framework/Versions/A/ProKit
00e23000 /Applications/Final Cut Pro.app/Contents/MacOS/../Frameworks/AVCVideoServices.framework/Versions/A/AVCV ideoService
If anyone wants to see more of that report let me know...
Thank you so much for your patience and assistance.
Sincerely,
Tracy

First, I think your workflow is more complicated than it needs to be. If the media resides on both systems on drives with the same name and same folder structure, you shouldn't need to relink. FCP should find the media transparently.
If you have a corrupt piece of media, this might work. Try this, with the media drive disconnected, open the project and do a save as. Quit fcp and then reconnect the media drive and launch the project. You should get the reconnect window. Do not reconnect anything at this time. Then, gradually reconnect your media until you find the problem clip.
If the problem is corruption in your sequence, follow the initial steps above, but after cancelling the reconnect on startup, try creating a new sequence with the same settings as your existing sequence and copying the contents of the existing sequence to the new sequence. Then select the new sequence in the browser and control click and choose reconnect media.
Report back and if the problem still exists we can move on.

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