Disk error that I can't repair despite logical steps

1. I ran Disk Utility within OSX and detected a disk error but the option to repair was grayed out
2. I ran my back up system to ensure I have an up-to-date clone on my LaCie external HD
3. I booted Norton Utilities from CD which couldn't repair the error
4. I ran Apple Hardware Extended test which said there were no hardware problems
5. I began wondering if it was a software issue rather than a hardware one...
6. I booted Disk Utility from my Tiger Install DVD which also detected a disk error but could not fix it
7. Thinking that reinstalling Tiger might do the trick, I tried to 'Archive and Install' Mac OS X Tiger from the DVD twice, but each time it was unable to complete the install and asked me to start over again
Any ideas how to fix this error?
I am working quite intensively with iMovie at the moment, which crawls on my 3 year old 1 GHz PowerBook. One file has grown to a whopping 18 GB in size. Could this be part of the problem? I performed permissions repair, disk verification and defrag successfully last week before starting on my iMovie project, so the system was pretty well optimised, I thought.

Thanks, Miriam. I regularly run Utilities to ensure my system stays in good condition. Especially as I work with images a lot and sometimes - like now - with video. So, it was routine maintenance I guess. However, some applications have been a little slow to open or struggled to open files recently as well.
Regarding Disk Warrior etc, being an individual rather than a corporate user, obviously I'd rather avoid spending the money unless I absolutely have to. In addition, being in UK, it may take time for the disk to arrive and I don't think my nearest Apple Store stocks Disk Warrior - it's not on the UK online store anyhow (strangely). TechTool Pro is more expensive still. Sorry if I sound stingy, I just am being careful with my money. If I need to buy Disk Warrior, of course I will.
Thanks, A Brody, for the welcome. I regularly clone my entire system so I have a bootable backup, but thanks for the reminder anyway!
I appreciate the comments from both of you about Norton in this regard.
Since the Apple Hardware Extended test indicated no hardware faults, am I right to think it is probably more to do with software? Or should I be concerned about my hard disk or other hardware?
PowerBook G4   Mac OS X (10.4.5)   1 GHz PowerPC G4 | 1 MB L3 cache | 768 MB DDR SDRAM

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