The modified boot0 was from Zef's original code talked about in this discussion on the voodooprojects' forum, combined with this discussion with Rekursor.
That looks promising but I haven't tested it. Is this based on Zef's new code? (mentioned by rekursor).
Zef has shown that the fdisk supplied in the Chameleon binaries has already been modded to only write to the first 440 bytes. See his post on voodooprojects' forum.
Yes, the script I put together also works. Thanks for trying it and feel free to use my script (if it's still relevant) in your installer
Edit: It worked fine for me. Now I'll try to modify your code to work with the installer (ie varibles). I'll not release the installer with your code till you give me your consent.