Hello Jeff !
You've been doing some good testing!
I would need a few more details, such as for each P4 machine the exact specs, versions tested and exactly what you see, when you boot to CD, and once it is installed.
Also if you had to setup 5 seconds for the Grub screen, does it mean the machines have very low ram specs?
I am astonished to read the PAE versions work better for you than the non PAE, which would mean I need to consider continuing to provide both? Is it the 3.8 version? Why the wireless is not seen anymore: not sure, however it might be something related to some packages automatically removed after install.
In the ISO there are some filesystem.manifest files, I'll do a diff and see what is removed. (Again, is it the version with the 3.8 kernel which you have tried?)
Some news! Since I posted this message, a new contribution has been done by sudodu, (Nio) a great contributor to the Lubuntu team. He has helped me with some testing, helped with a zram-config bug solved since:
https://bugs.launchpad.net/ubuntu/+source/linux/+bug/1246664and for which the linux kernel 3.2.0 (the generic is the one I am interested in) just arrived in the current repositories.
The other news is Nio put up a "grub-n-iso" from Bento, which is a tweak they have figured out among a few Lubuntu contributors, in order to allow some Pentium M and Celeron M machines (with P4 cpu) to boot, when the CPU has pae capability but is not seen by the system and shown in the cpuinfo flags.
the version I provided with fake-pae will help when the system is already installed, but when it is not yet installed it needs Grub to be there to boot it, instead of syslinux. This is where his "grub-n-iso" comes in the scene. One question regarding the issues you met, are the machines you are having belonging to this category?
I don't have any machine falling into that category, so I could not test it. But here is a start for detailed explanation:
https://help.ubuntu.com/community/Bento-fake-PAEAll necessary links are there, courtesy to Nio and phillw, and the image done by Nio is also available here:
http://phillw.net/isos/bento-ubuntu-remix/bento-ubuntu-remix-RC-linux-3.8-fake-pae-i386-2012.04.3.grub-n-iso.img.gz 700M
bento-ubuntu-remix-RC-linux-3.8-fake-pae-i386-2012.04.3.grub-n-iso.md5sum
Let's see how it goes?
Have a good day too!