Hey Leo,
The instructions were good. I opened the website on my desktop and did all the work in front of the screen. The 40Gb would be better(you don't want to do this on a regular basis). Doing it your way (formatting after installation) means you will have to boot from a Mac OS CD or maybe TechTool Pro. Do you have Tiger on CD's? I don't know if Tiger will recognize the pc formatted hd and allow you to reconfigure it. I do know that last week I upgraded my iMac with a brand new hd (not initialized) and Tiger didn't see it. So I booted from OS9 and used the drive setup utility to initialize it. Tiger then loaded. I don't have a torx 8 either. The right size electronics screw driver will work (it did for me) because the screws weren't very tight. Finally, I'm responding to you on my Clamshell, wirelessly, with Tiger on a 40Gb and a 512mb ram stick installed. It seems to be working fine for me. Good luck.
Leon...