Glad you got things working.
Quote:
...the upgrade script missed INSTALL.i386 ...
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I'm guessing you mean INSTALL.macppc.
You did not need to use a flash drive. You can install filesets downloaded to your local hard drive. You just need to note that any automatically mounted filesystem in your /etc/fstab will already be mounted under /mnt by the upgrade script, and select an already mounted partition and the appropriate directory, accordingly.