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Classic Startup
I went through your pain regarding Classic on a restored Mac OS X system a couple of months ago. The culprit is that items used in the 'Classic Startup' seem to have some very precious resource forks that seem to get butchered in rare circumstances. I *think* if you go to /System/Library/CoreServices, and go into the Package Contents of 'ClassicStartup', and then drill down to Contents/Resources/English.lproj/SystemFiles you might find that items are reporting a size of Zero K. If you have your old Mac OS X system folder somewhere, or even still have access to the loaner box, you can try copying the original files in there. I remember it being a tricky process due to permissions and the like. Plus, I thought "Oh, I can just tar.gz the files I know are good, and do a sudo decompress in the right place and have everything work!", but tar/gz kills the resource fork. I can't remember exactly how I resolved it all. But that and a recent CD and/or software update's deep package innards would be a good place to start. Sorry I don't have any more to offer, but it does sound like you're going through the same situation I went through. Good luck!
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