Error: invalid key kength

Getting some strange occurrences:
-unexpected quits more unexpected than usual
-my keychain disappearing and not being able to make a new one
-my drop box (shared folder) disappearing
-hard crashes with FireFox and my flight sim
The computer still works (typing from that boot partition now) but I need the drop box back so we can move some files for CD archiving from the wife's old iMac to her new eMac that arrives tomorrow.
I booted from the OSX Jag install CD yesterday and ran Disk Utility on the OSX boot partition. Its repair function reported an "invalid key length error." Running Repair Disk several times would report it fixed and then not fixed.
Searching the forums here, I know what I need to do to correct it. Nearly all information says that even DW cannot correct this. About half the responses to reports of this error say that it's a sign the the drive is dying, the other half say that wiping the partition and reinstalling should take care of it.
Out of an abundance of caution, I ordered a new 120GB drive today (on sale at Staples.com for only US$60!). However, I want to try the reformatting first. Any thoughts on whether the drive is going belly-up??
The boot partition is on a 60GB drive that is somewhere between 3 and 4 years old. The larger slave drive is less than two,
Here's my plan:
1) remove the CD-RW and ZIP, and make the 80GB slave drive "master" on the ATA1 bus.
2) Use Carbon Copy Cloner to move the boot partition (on ATA0) to a reserved 7.99GB partition on the 80GB drive (boy! Am I glad I set that up when I installed the drive!)
3) Wipe the orig OSX boot partition and zero it out with DU.
4) boot from the cloned partition
5) Again use CCC to move OSX back to the orig partition.
DU reported no problems with the other three partitions. I also have the option to simply make a new install of OSX on the 80GB's first partition.
Anyone see any potential problems with my plan? Hand-holding and sympathy cards are appreciated!
Allan
[4079]

Thanks Grant,
I thought that the error is due to a directory problem. But you're right--CCC probably can't read a damaged directory properly.
When I searched the forums, most posts were of the line of "DW can't fix this." Just about every report said that the problem did not go away for good until the partition was zeroed out and the system reinstalled.
Anyway, the current version of DW is not for Jag, apparently, None of the downloads show anything but the latest version.
I bought TTP3 before they came out with the OSX v4 and was sent a free upgrade CD. It boots into Panther--no go. They then sent a "Beige" version that had 10.2.6, but I managed to unbless the boot partition with it, requiring an A&I last November. The nice TTP tech I contacted basically said the TTP4 should not be used on a Beige G3 without an ATA accelerator card. By then, a Jag version of DW was not available. So I'm stuck without a heavy duty OSX utility at the moment.
I think it may be best to wait until Thursday when the new drive gets here and set it up as the new boot drive, leaving the 2-year old 80GB as the slave.
At least I'm running OK right now. I know not to try FireFox or my flight sim until lI get things patched up. The new eMac arrives tomorrow and I was going to move a bunch of Susan's files to my computer while setting up the new toy. My wife may have to wait.
A

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