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I am sure there is a more extreme answer to this but I installed Tiger onto a 4Gb USB memory stick, including Diskwarrior, by simply using the Tiger install disk, selecting options at the appropriate point, and unticking everything I didn't need, languages, printers etc etc. It was pretty straightforward and it works.
Disk Utility tells me it has used 2.8 Gb out of 3.5 Gb capacity.
Don't forget to put a GUID partition table on it if using it in an Intel mac.
Mike
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