🚀 go-pugleaf

I can't get Suitcase to work any more!

Running 4.1/5.5 on a 512KE w/2MB, MacBottom serial with 2.91 SW.
This was my standard case.  Steve Brecher talked to me and we finally found
that Suitcase had to be in the System Folder on the startup disk,
and in the root on the HD for it to work.  Fine (for a month).  Last night
I had a problem related to my keyboard cable, and blew the startup disk. 
I rebuilt it from the archived original, and now, no matter what I do, it
blows with a System 03 (when transferring to the HD, I think).  The fix
is to take Suitcase out of the System Folder on the startup - all works
fine then, except that I don't have the use of Suitcase (a fate worse than
death after you have used it for awhile).

Anyone have any ideas?  For example, I moved new system and finder files
from my original Hypercard disks, just to be sure I had a 'real' copy. 
I placed the same files on both disks, just for consistency.  I did nothing
with the '4.0 BootBlocks' file.  Should I have??

Help, please.  Anything would be appreciated.

Thanks...Gary