Reinstalling 10.4 after failed 10.4.5 upgrade

Having trouble getting 10.4 reinstalled on my mini after the 10.4.5 upgrade (system was running fine on 10.4.4) borked the login process.
The story up to now...
Mac mini (1.25/40GB/1GB/Combo) was running 10.4.4 with no problems.
Downloaded and installed 10.4.5 upgrade yesterday - on reboot system went from white screen to blue screen (no login prompt) to black (single user login mode). Produced a number of errors regarding "udsserver_init: bad file descriptor".
Finally decided to just reinstall 10.4 from the DVD that came with the mini and redo the upgrade process.
Problem: every time I try to install 10.4 from the system DVD, I get "There were errors installing the software - please try installing again" part way through the install process. So far I have:
- install keeping previous system settings (eg user account info)
- erase the internal disk using Disk Utility (on the DVD) and then install
- clear parameter RAM, erase disk, and install
The install fails each time, though not necessarily in the same place. Restarting and trying the install again seems to allow it to go a bit farther, but mayby that's just my imagination. System was problem-free with 10.4.4.
I'm out of ideas - any other hints?
K
Mac Mini   Mac OS X (10.4.4)  

More info -
Decided to try installing using an unopened retail copy of Tiger I had laying about rather than using the mini's install DVD. No joy - same result - install always fails during the Essentials portion of the install. So the DVD doesnt seem to be at fault.
The Tiger retail installer did invoke a crash log - the first line says:
"BomFatalError - cpio read error: bad file format"
As a last-ditch effort, I stuck the Tiger install DVD into my PowerBook, put it into Target Disk mode, and then plugged into the mini's FW port and used the PB's SuperDrive to run the install ... and got the same result - the install fails somewhere in the middle of Essentials. So I guess the combo drive is not at fault either.
Interestingly, the mini happily booted from the 10.3.9 image on my PB's hard drive. I thought that OS installs were more closely tied to the hardware...
At this point I cry uncle - I assume I have some sort of disk or IO subsystem problem beyond my control. Time to see if the extended warranty I bought with this system (it's about 6 months old) is worth the extra money I paid.
Keith

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