Sorry but I do not understand single thing you are posting.
I use CURRENT all the time, but I do not reinstall CURRENT from install disk all the time.
The sysinstaller is probably broken because it does not use gpart at all, you can manage partitions with gpart, do not use other tools.
You can install boot code to mbr/slice with gpart.
New installer is not yet complete.
To correctly install CURRENT you should probably use gpart in fixit shell.
You can post "flames" on @current mailing list, posting it on this forums is like talking to wall.
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