Tiger fails to install to external HD partition

So I've been trying to install 10.4 to a "rescue" partition of my 320 GB external hard drive. I've partitioned about 6 gigs to use as a bootable backup in case my internal HD (also partitioned) fails, while the other partition is used for storage.
After several failed attempts - each a "clean install", and each with a full partition erase via Disk Utility prior to attempting a re-install - I tried removing my two 512MB third-party RAM modules. I read about third-party RAM conflicts in these boards, and decided to try and re-install using the original RAM I got with my Pismo (an included 64 MB chip - by itself, not enough to even boot to the Tiger disc; and an additional 128MB chip I got free when I bought my PB).
Again, no dice. Just as always, it installs the Base system successfully, but after about 9% of the Essentials are installed, the progress bar hangs, and I get the error message: "Please try reinstalling."
Here's the relevant excerpt from the install crash log:
Feb 3 18:35:25 localhost : BomFileError 5: Input/output error - ./Library/Fonts/Kai.dfont
Feb 3 18:35:26 localhost : 3076 files looked up in 0.28 seconds. 3076 files written in 34.84 seconds.
Feb 3 18:35:26 localhost : 53052 kilobytes installed.
Feb 3 18:35:26 localhost : Install failed: Some files for Essentials may not have been written correctly.
A font? A font is thwarting my Tiger install? Come on, now ... I'm not buyin' it.
If anyone's got any ideas, I'm all ears.
Thanx
Powerbook G3 Firewire (2000 Pismo)   Mac OS X (10.4.4)   100 Gb internal HD, 1 Gig RAM

Acomdata 320 GB drive: HD320UFAPE5-72 made in May of '05. Firewire/USB combo, I think it's an Oxford 911 chipset. Got it this summer, haven't had any issues with it. I didn't try to install OS X on the Backup partition because it was simply going to serve as backup, although I've got bootable .dmg clones of my and my girlfriend's hard drives on it.
Another attempt (same circumstances, haven't increased partition size yet) this afternoon and I'm still stumped. Look at the contents of the drive after a failed attempt (all are folders, unless indicated):
Applications (incomplete, only contains AppleScript, Internet Connect, and Utilities)
bin
dev
etc (alias)
Library
mach_kernel (file)
OSInstall.mpkg.107OCmgEG
private
sbin
System
tmp (alias)
usr
var (alias)
Volumes
It's failing before it gets a chance to hide invisible files and folders, although the installer says it's finished with the System and is onto Essentials when it stalls.
Geez, I dunno...
Powerbook G3 Firewire (2000 Pismo)   Mac OS X (10.4.4)   100 Gb internal HD, 1 Gig RAM

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