Before you do it, I have one last crazy thought. I'm still thinking an oddity occured when flashing hboot. I think it could be possible that some data may have been placed onto the cache partition. If the unzipped Rom files go there also, even temporarily during the unzip process, maybe your cache partition is too full to accept any further flashing activity? (That's why I asked the question above)
Bottom line, it's speculation but it's also one last easy thing to try. Wipe the cache partition ONLY using Clockwork and then give Rom install one last shot from SD. Maybe you already tried that when attempting the Rom flashes, IDK. Other than that I'm out of ideas.
Best of luck.