Good info. Thanks!
I do not recall the slot-loading iMac G3s requiring the <8GB boot partition for OSX. The tray-loaders probably did.
No sure of the exact issue but yours seem to parallel the startup problems I mentioned above. We hade no issues starting in OS9; no joy with 10.3 or maybe it was 10.4.
...even the CRT broke as all the plastic due to the extensive heat and use...
I see you appreciate the iMac G3 heat issues. 🔥🚒🥵
I attributed our issues to heat. The iMac DV SE (Summer 2000) 400mhz was my wife's. We had retired in working order. One of the kids needed a computer fast when her ex got theirs. I pulled out the G3, installed a larger hard drive, more RAM (from 64MB to 256MB), and either Panther or Tiger—can't remember now—that was 20ish years ago.Both OS versions worked in our house which has year-round conditioned air.
It worked for my daughter as well at first, but she lives in Portland, OR. There, few rentals have air-conditioning and their summers were getting hotter. During one heat wave, the iMac shut down when temps exceeded 90°F in her living room. After cool-down, it would only restart in OS9. Now it's back here in the drier eastern foothills of the Rocky Mountains and still won't start in an air-conditioned house.
There was a lot of chat here back then about bigger, faster aftermarket drives causing more heat issues than did the G3 factory drives. Some people "enhanced the G3's convection-only cooling because the PAV (power-analog-video) board got cooked by the bits below it. Air needs to go from bottom to top.
Some set their iMacs on one of those fan-equipped "chill pads" for laptops. The pads needed to be a single-fan design to focus as much air as possible directly into the vent holes on the bottom of the iMac case.
The most effective solution for cooling was to screw or glue a 120mm computer fan from a big desktop computer over the iMac handle area where the hot air exhaust is. The fan had to be oriented so it pulled air up and out. "Pull" moved more air that "push.
The latter had two big issues. The fan mounting permanently damaged the case, and one has to get power to it without the danger of exposed wiring.
Just a bit of history that might trigger some ideas for you.
Cheers!