Main drive won't boot reliably

If I have a duplicated ( via SuperDuper) external drive attached, the OS will boot from that drive, even if I have my main drive selected in prefs as the startup drive.
If I disconnect the external drive, my mac will boot from DiskWarrior DVD, in the Superdrive.
If I remove the disk, my drive gets me a flashing question mark.
I have DiskWarriored and TechTooled and they pass the drive, yet all the above indicate that all is not well with my main drive.
Yet in each case, if I start with 'Option' key pressed, my main drive appears in the list and will then boot happily and will run all day.
Any ideas as to why the drive won't boot OSX straight away?
tia
peter

good job on having firewire ports, you can run tiger.
to upgrade the firmware, you need to install a harddrive that has OS 9 on it. doesn't matter if the drive is in that computer at the moment, it can be a friends that has it installed already. you just need a installation of OS 9. Connect it to the internet after its booted, run the software update, it'll reboot some times and some junk and do it for you. Be nice and give the hard drive back to whoever was nice enough to lend it to you. They are SUPER easy to swap.
My impression of your hard drive is that it is failing its SMART crap. The problem with these things is that the heat they live with (cause of the proc and the crt in there, not to mention the psu) make them "stretch" as they work. you "can" dent the little disc/circle lookin part on the top of the hard drive with a hammer very lightly and sort of "force" it back in to a more optimal position for old age. Since i saw you just ordered a new hard drive from ebay (newegg would have been more trustworthy, ata 100 backwards compatability for the win), when you get that, put it in and come up with an OS 9 install disc. Gotta be one for your computer or a retail, which did or does come with tiger when you buy it.
I installed OS X Tiger on my iMac G3 400dv without doing the firmware update first and i updated it to the current version, did it break my monitor? nope. BUT, it says it can, so i'd install OS 9 first and do the firmware update like a good person would. I have since installed OS 9 and fixed the error on my part and reinstalled Tiger.

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