Mini won't boot up from internal hard drive

Greetings,
I can't get my Mac Mini to boot from it's internal hard drive. It just gets stuck at the grey apple screen wth the spinning gear, nonstop. Booting in safe mode produced the same behavior (still wouldn't boot). DiskWarrior fixed some directory problems and found some corrupted microsoft office files which I deleted but it still won't boot. It boots fine off an external USB drive.
I've tried disconnecting all peripherals except keyboard,  mouse, and monitor, resetting NVRAM/PRAM, and reinstalling the OS over the existing one (but not a clean install).
Disk Utility and DiskWarrior both now say the boot drive is fine, but of course it still gets stuck at the grey boot screen.
Booting in verbose mode it shows the following errors and then hangs:
disk0s2: I/O error.
0 [Level 3] [ReadUID 0] [Facility com.apple.system.fs] [EffType IO] [ErrNo 5] [IOType Read] [PBlkNum 533720112] [LBlkNum 0] [FSLogMsgID 884471847] [FSLogMsgOrder First]
  0 [Level 3] [ReadUID 0] [Facility com.apple.system.fs] [DevNode /dev/disk0s2] [MountPt /] [Path /usr/llbexec/configd/ ..namedfork/rsrc] [FSLogMsgID 88471047] [FSLogMsgOrder Last]
/SourceCache/AppleFSCompression/AppleFSCompression-24.4/Common/commonUtilsKern.c :344 VNOP_GETXATTR com.apple.ResourceFork for /usr/libexec/configd: 5: error
/SourceCache/AppleFSCompression/AppleFSCompression-24.4/Compressors/Type4/compre ssorTyp4Imp.c:328: readBytes /usr/libexec/configd: -1: error
decmpfs.c:1307:decmpfs_read_compressed: decmpfs_fetch_uncompressed_data err -1
Other than a complete wipe and reinstall I don't know what else to try.
Thanks!
- LW

Hmmm,
  qErr                     
= -1,   /*queue element not found during deletion*/
Failing in  /usr/libexec/configd makes me think some file like...
/usr/standalone/bootcaches.plist
/private/var/db/BootCache.playlist
Is possibly corrupt.

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