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OSXS v.10.2 installation problems - ugh!

Fellow listers, we spent a full day (26 hours, actually) this weekend miserably failing to install OSXS v.10.2 on the following machine:

Beige G3 mini-tower with:
* 266MHz CPU (rev. a)
* 384MB RAM
* Asante 590 "Fast" 10/100 PCI Ethernet card
* Existing 9GB Barracuda SCSI HD on the internal SCSI bus
* 40GB Barracuda ATA HD on the internal ATA bus (new drive)

Using the Disk Utility from the OSXS installer CD, we partitioned the 40GB drive into a 7.9 partition and a 32GB partition, making sure that the smaller partition was in the first 8GB of the drive. So far, so good. Anyway, no matter what we did, when attempting to install OSXS on the 7.9GB partition, the process would never finish, seeming to freeze at different points during the installation.

In an attempt to work around the problem, we moved the 40GB drive to the on-board ATA bus of a blue and white G3 with 768MB RAM, and tried the same thing on that machine, only to have the same problem occur. Then, out of desperation, we installed a copy of OS X v.10.2 "client" on the drive in the hope of being able to boot into OS X and install OSXS on top of it, but the Finder kept crashing after log-in, although it did manage to send the registration info off to Apple, so I know it was talking to the network. BTW, it took six tries to get OSX "client" shoved down the blue and white G3's throat.

Feeling beaten, I moved the 40GB drive back to the beige mini-tower, and instead of hooking it up to the ATA bus, I connected it to the same bus the CD-ROM drive is on in that model, and -- voila -- it booted just fine into OS X (still the "client"), except that it wouldn't recognize any of the passwords I'd set up when I installed the OS. I tried resetting the passwords using the utility on the installer CD, but that didn't work.

In the end, I booted into OS 9.1 from the 9GB SCSI drive, wiped the 7.9GB partition, copied the contents of the SCSI drive to it, set the startup disk for the 7.9GB partition, and rebooted the Mac. Naturally, it worked fine booting into OS 9.1 with AppleShare IP v.6.3.3 from the 7.9GB partition, so I'm left wondering what we did wrong, and what we can do to migrate this beige G3 to OSXS v.10.2.

TIA for any and all suggestions.

Ted "tired and frustrated" Dively
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