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I've been away from avr development for a few months...turns out that the current combination of gcc-avr and avr-libc (has been flagged as out of date since 2011-05-30) but has not been working for since gcc-avr was upgraded on 2011-04-22.
The small piece of Teensy code I was compiling successfully, is now crashing the compiler:
-------- begin --------
avr-gcc (GCC) 4.6.0
Copyright (C) 2011 Free Software Foundation, Inc.
This is free software; see the source for copying conditions. There is NO
warranty; not even for MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.
Compiling C: main.c
avr-gcc -c -mmcu=at90usb1286 -I. -gdwarf-2 -DF_CPU=16000000UL -Os -funsigned-char -funsigned-bitfields -ffunction-sections -fpack-struct -fshort-enums -Wall -Wstrict-prototypes -Wa,-adhlns=./main.lst -std=gnu99 -MMD -MP -MF .dep/main.o.d main.c -o main.o
main.c:1:0: internal compiler error: in dwarf2out_frame_init, at dwarf2out.c:4260
Please submit a full bug report,
with preprocessed source if appropriate.
See <http://gcc.gnu.org/bugs.html> for instructions.
make: *** [main.o] Error 1
Now I know the Arch policy of not reporting bugs on out-of-date packages, but the current combination does not work (I'll be reporting a gnu bug shortly, if it already hasn't been done). I may be mistaken, and this could just be a problem with the gcc-avr compiler.
Source code is available http://gitorious.org/kiibohd-controller
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Hmm, looks like it may have been very recently resolved: http://gcc.gnu.org/bugzilla/show_bug.cgi?id=48459
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