OS X Mavericks installations fails after reboot, stuck. Safe mode does not help

Question

Quick Summary: Installation of Mavericks gets stuck after reboot, no safe mode boot, only recovery console works.
Update:  Currently following procedure http://support.apple.com/kb/TS2570?viewlocale=en_US
I have upgrade 4 out of my 5 machines, but the most important iMac 27" mid 2010 went through with the installation and then got stuck on a grey screen with the apple logo and a spinning wheel for 6 hours.
A few restarts did not help.
Started from recovery a new download and install. But it ended up in the same end.
Trying safe mode/boot, but does not finish
Going back to recovery and try repair disk, does not help
Going to recovery using terminal resetpassword and then setting the permissions for all login accounts back, no good.
Going to recovery and using terminal to check /var/log of the mounted Macintosh HD.log shows at the end "The installation was successfull"
System.log shows
com.apple.kextd: Failed to send personalities to the kernel.
Error: Couldn't send kext personalities to the IOCatalogue.
Exited with code: 71
Throttling respawn: Will start in 8 seconds.
Resetting NVRAM/PRAM and reboot, waiting so far stuck but I still hear some disk activity, waiting a little bit longer.
Any help?

Answer 1

Do you have a Recovery HD from your previous systems?
Boot Using OPTION key:
  1. Restart the computer.
  2. Immediately after the chime press and hold down the
      "OPTION" key.
  3. Release the key when the boot manager appears.
  4. Select the desired disk icon from which you want to boot.
  5. Click on the arrow button below the icon.
Look for another Recovery HD, although you need the OS 10.9 one if it's available. If it's not, then you will need to start over from scratch by erasing the drive then reinstalling 10.9.
Install or Reinstall Mavericks, Lion/Mountain Lion from Scratch
Be sure you backup your files to an external drive or second internal drive because the following procedure will remove everything from the hard drive.
Boot to the Recovery HD:
Restart the computer and after the chime press and hold down the COMMAND and R keys until the menu screen appears. Alternatively, restart the computer and after the chime press and hold down the OPTION key until the boot manager screen appears. Select the Recovery HD and click on the downward pointing arrow button.
Erase the hard drive:
  1. Select Disk Utility from the main menu and click on the Continue button.
  2. After DU loads select your startup volume (usually Macintosh HD) from the
      left side list. Click on the Erase tab in the DU main window.
  3. Set the format type to Mac OS Extended (Journaled.) Optionally, click on
        the Security button and set the Zero Data option to one-pass. Click on
      the Erase button and wait until the process has completed.
  4. Quit DU and return to the main menu.
Reinstall Lion/Mountain Lion: Select Reinstall Lion/Mountain Lion and click on the Install button.
Note: You will need an active Internet connection. I suggest using Ethernet if possible
            because it is three times faster than wireless.