Replacing HDD, can't format

I'm replacing the broken HDD in my 2006 white MB with a WD1600BUDT ( http://wdc.custhelp.com/cgi-bin/wdc.cfg/php/enduser/stdadp.php?p_faqid=5383&p_created=&p_pv=2.327&pprods=227%2C327 )
and it was giving me a I/O error when I tried to format it with my 10.4 grey disk. It also showed up as being a 1.2 TB drive instead of the 160GB that it should be.
So I popped in my iMac's 10.5 grey disc to see if disk utility would allow me to format the drive there. It shows up properly as a 160GB drive there, and allows me to format it. However once I go back to the 10.4 disk to try and install the OS, the formatted partition I created wont mount.
I remember reading on WD's website that the AV drives were compatible with 10.4 and up, so I'm really hoping that I don't have to buy yet another hard drive.
Any suggestions?

Thought I would type up the solution I found in case anyone else stumbles across this page on google while looking for help.
There's no way to make this HDD work with 10.4, however 10.4.11 will work. So what I had to do was take an old hard drive I had (that had a bootable version of OSX) and plug it up with an external usb case, then boot from it and partition a small part of the drive (15 GB) and install the grey 10.4 disk onto that partition.
Once 10.4.11 was installed on the partition, I ran disk utilities from there and formatted the internal drive successfully!
Then I booted back to the main partition on the usb-connected hard drive, and used a free program called Carbon Copy Cloner to copy everything from the 15GB partition to the internal drive. Ah sweet success. Now if only it hadn't taken me all night to figure that out! lol

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