Yes, I don't recall the full details but I was attempting to build it 
with -O3 and dropping the CFLAGS resolved it.  I've never seen it fail 
like this with unless non-default CFLAGS were set though.  The entire 
build was heavily optimized and I eventually scraped it - by the time I 
was getting into the multimedia section the of BLFS the results were too 
unpredictable.

Trent Shea wrote:
> Has anyone experienced this error when running make check on grub-0.97? The 
> test fails when building trunk Revision: 8935 (in chroot, and if I boot into 
> the 6.5 system and build.)
>
> make[3]: Entering directory `/grub-0.97/stage2'
> ffs_stage1_5 is too big (8008 > 7168).
> FAIL: size_test
> =================================
> 1 of 1 tests failed
> Please report to bug-g...@gnu.org
> =================================
> make[3]: *** [check-TESTS] Error 1
> make[3]: Leaving directory `/grub-0.97/stage2'
> make[2]: *** [check-am] Error 2
> make[2]: Leaving directory `/grub-0.97/stage2'
> make[1]: *** [check] Error 2
> make[1]: Leaving directory `/grub-0.97/stage2'
>
>
> I eventually got it to pass the test by using the following CFLAGS:
> export CFLAGS="-march=i486 -mtune=native -Os"
> I copied the first flags from the glibc section and had to add '-Os' to get 
> the size down. I'm really out of my element here, so any review on this 
> approach would be appreciated.
>
> I referenced http://en.gentoo-wiki.com/wiki/CFLAGS for the '-Os' flag.
>
>
> Trent.
>   
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