Repeated restart/bluescreen with clean install of Tiger

Hi,
Been running 10.4.7 just fine on my dual G4 MDD/FW800 Mac. I only had the original 128GB hard drive plus an external 250GB hard drive.
I added an internal 500GB hard drive, split it into two equal-sized volumes, ran a verify/permission check and things are fine on the new drive.
My plan was to copy/clone the existing boot disk image over to the new disk for more room. Along the way, I tried to remove an emergency boot drive from Tech Tool Pro (on the original drive), and this rendered my original drive un-bootable and unrepairable by the Disk Utility via the installation disc. I believe I have most of my data backed up, but I would like to avoid re-formatting that disk for now.
So I figured I'd simply re-install a fresh version of Tiger to one of my new volumes on the new 500GB drive. I had checked into this, and I believe my MDD/FW800 machine can tolerate a drive this large. Plus, disk utility didn't complain, and it all looked good after partitioning.
I ran the Tiger installer, pointing to a completely new install onto volume1 of the new drive. Install went fine, then it re-booted. When it came back up, it said that I need to re-start my computer (blue screen with a gray box and this message in a few different languages). Okay. Done. Then the screen comes up again. Re-start. Same screen. Again and again.
I have tried to install probably a half-dozen times now. Once I was lucky enough to hit the welcome screen after the reboot, and then when I hit the "transfer data from another partition" option (hoping that the file system on my original/old drive was still readable even if I could not boot), it told me to re-start, and then I got into that loop again.
I have run the Apple Hardware Test CD in loop mode overnight, and no problems were reported after 12 iterations.
Any suggestions? Can this computer model really tolerate a drive larger than 128GB? I'm hesitant to try and re-format my original one (in case there's something there that I did not back up and I can read it later) just yet and install to that.
Oh, along the way, when I could not get the TechTool disc out of the machine (and before I discovered the process of booting to Open Firmware and using the 'eject cd' command) I had tried to open the CD drawer with the manual pinhole. At some point, the disc started spinning again with it open a bit, and it sounded nasty...I don't care much at this point if the TechTool disc was damaged, but I think the DVD drive is just fine as the installer can verify it's own installation/disk image and I can boot to it or the hardware test CD just fine.
Joe
dual G4 desktop, MDD, FW800   Mac OS X (10.4.7)  
dual G4 desktop, MDD, FW800   Mac OS X (10.4.7)  

I was able to boot into safe mode after re-starting the machine. Then I immediately took the OS and all other software updates. Eventually after that I could re-boot consistently. Thank goodness for the Backup program. I had all my user settings, music, pictures, desktop, document files, address book, iCal settings, etc. backed up, so it was pretty easy to restore it all.
I'm still not sure why it would not re-start correctly just after the Tiger installation.
dual G4 desktop, MDD, FW800   Mac OS X (10.4.7)  
dual G4 desktop, MDD, FW800   Mac OS X (10.4.7)  

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