Having read many Apple support documents on apple.com since the last post, I have realized that there are many things that I didn't try that could have been fixed the problem (besides running the various disk utilities). Here are some links to the most useful ones, which for many of you is like "duhhhh", but maybe someone could find these breadcrumbs useful:
"Troubleshooting installation and software updates"
http://docs.info.apple.com/article.html?artnum=106692> > >
Installation fails during "optimization"
If the installation fails during "optimization," all of the software was installed. There is no risk of an "incomplete installation." The optimization phase of an installation only affects performance and not stability or features. You may force optimization to be repeated by reinstalling the software. If you were using the Software Update pane of System Preferences on the first attempt, you will need to download the standalone installer of the same software from Apple Downloads in order to reinstall the software.
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"Your Mac Won't Start Up in OS X"
http://docs.info.apple.com/article.html?artnum=n106464Lots of good info in here... talks alot about moving preferences out of the System folder and trying again.
"Mac OS X: How to troubleshoot a software issue"
http://docs.info.apple.com/article.html?artnum=25398> > >
If the issue does not appear to be related to preferences, a login item, or a kext file, and persists in Safe Mode, there may be an issue with acache file in your home folder:
Go to ~/Library
Drag the Caches folder to the desktop.
Attempt to reproduce the issue.
If issue is resolved, drag the Caches folder to the Trash.
If issue persists, go to /Library.
Drag the Caches folder to the desktop.
Attempt to reproduce the issue.
If issue is resolved, drag the Caches folder to the Trash.
If issue persists, go to step 4.
Tip: The Caches folder is similar to the Preference folder in that each time an application is opened, a new file is written. It is not necessary to troubleshoot these files.
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"Update and Before You Install Information"
http://docs.info.apple.com/article.html?artnum=106300> > >
If you experience a power outage or other interruption during a software update installation, you should download the standalone installer from Apple Software Updates and reinstall it. "Optimizing" refers to the execution of a process called "update_prebinding," which allows applications to open faster by precalculating the address information of system data the applications use. This optimization is performed on the Mac OS X startup disk when Apple updates certain system components. Though update_prebinding may be executed manually, it is not necessary to use it at any other time.
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"About the Archive and Install Feature"
http://docs.info.apple.com/article.html?artnum=107120At the bottom it has links to a lot more.
There was also an article that talked about moving the /Library/Caches and ~/Library/Caches folders to the desktop to help solve problems. In that vein, I also thought maybe this is worth a shot:
"OS X Odyssey 337 - Desktop Rebuilds and RebuildDesktopX 1.0"
http://www.applelinks.com/articles/2003/06/20030604110107.shtml> > >
Then there's SubRosaSoft's RebuildDesktopX, a freeware utility for cleaning various caches on OSX that store information relating to the application binding, icons, etc. Not exactly the same as the old Desktop rebuilds in Classic, but probably worth running once in a while, especially since it's freeware.
For the UNIX literate, this program executes the following commands;
/bin/rm ~/Library/Caches/com.apple.LaunchServices.UserCache.csstore
/bin/rm /Library/Caches/com.apple.LaunchServices.LocalCache.csstore
/bin/sync
/bin/reboot
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Hopefully one of those things would solve the problem, rather than having to do an "Archive and Install". Part of the transition from OS 9 I suppose is learning where the preferences and things are that can be the first place to look when problems crop up, at least, if disk repairs don't do the trick.
-=DG=-