Building buildroot 2012.02 form arm / arm7tdmi, EABI, buildroot toolchain, Linux 2.6.24, uClibc 0.9.33.x, binutils 2.22, gcc 4.6.x, elf2flt enabled, enable large files. Error building uClibC: libc/misc/internals/errno.c:8:1: internal compiler error: in do_assemble_alias, at varasm.c:5444 Please submit a full bug report, with preprocessed source if appropriate. Host is 64 bit Ubuntu 10.10 I think. I can repeat error by doing make clean and then make again.
Did you try with another gcc version? I wouldn't prioritize this as blocker though, since it's an upstream bug rather than a buildroot one.
There has been several reports of similar problems on OpenWRT (https://dev.openwrt.org/ticket/11827, https://dev.openwrt.org/ticket/12267, https://dev.openwrt.org/ticket/11775), and apparently, each time it was caused by builds being restarted without a full clean. Since the user has reported this more than one year ago, and hasn't answered to questions also asked on year ago, I'm closing this bug. Erland, if you still have this bug with the last Buildroot version, do not hesitate to reopen it, and provide your Buildroot .config file so that we can reproduce it. Thanks!