Finally got it to work with a Pismo last night, so I just cloned that drive/OS rather than the one on the Lombard. I was able to reformat the drive and then CCC clone the drive. Yeah, it did take several hours, I knew it would be slow, but better than the gazillion separate updates when going from 10.4.6 to 10.4.11.

Tonight I'll swap out the drive in the Lombard and see if the new drive works successfully as a boot drive. Fingers crossed! It hit one bit of bad data on this drive, a dictionary. Interesting as that hadn't been caught before in the disk repair on this HD. Must be a very small bad sector of the disk.