I have a 6.0 installation without a /var slice. Instead I have a soft link
of /usr/var to a /var@ file. Now I am attempting an upgrade to 6.4 and
getting an error condition. I am using Disk 1 of the 6.4 distro >> Upgrade
[Upgrade an existing system] >> All [All system sources. binaries and
X-Windows System] >> added Ports and mount points. System goes through its
fsck-ffs -y routines on /mnt/dev/* devices.
=>> Error Messages
[i] "Error mounting /mnt/dev ad0as1e on /mnt/usr : Input/output error"
[ii] "Error mounting /mnt/dev ad0as1f on /mnt/usr : Input/output error"
Then tries to a form a holographic shell
asks for directory to save current /etc?, prompts with /var/tmp/etc, I
changed it to "/usr/tmp2/etc" => "Unable to backup your /etc int
/usr/tmp2/etc. Do you want to continue anyway?"
Opt'd out w/ a No! selection.

Could this problem result from the absence of a /var partition ? 
Is there an alt. Strategy for a 6.0 =>6.4 upgrade, while maintaining all the
previous custom and configuration files?
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