How are you all getting the Leo Install so small to restore it to the dmg? I've been working for hours and mine went from 7.XGB to 4.4GB at the moment, still too big, with almost no apps and everything that you said to delete plus ALL languages from the apps (Get Info>Languages>Delete all but english). How can yours possibly be 3.8GB without deleting tons of stuff that isn't listed here? Am I missing something? Yes, I went into Private/var/vm/ and got the swap and checked for the sleepimage but I don't have that enabled so it wasn't there. (Yes i had view hidden files on.) Also I deleted many fonts and all screensavers except for current. I deleted all voices including current and all else in the speech folder as well.
Download monolingual and wipe all the ppc crap out of your apps and system files.
Ok, great. The DVD boots fine, but the entire volume is corrupted in permissions, so I have to repair them. The problem is, how do I repair that volume?
dd the imagefile to an empty hd. Once it is there, just repair permissions from your actual Leopard installation and after that use the diskutility to save it back as an image.
just hdiutil attach the image with the option -readwrite -owners on