I've just posted some more details to ticket #3152 which is currently
closed.  Could somebody with permission to do so, please reopen it?

Basically, I'm getting:

b43-phy2: Broadcom 4318 WLAN found
phy2: Selected rate control algorithm 'pid'
Broadcom 43xx driver loaded [ Features: NLR, Firmware-ID: FW13 ]
input: b43-phy2 as /devices/virtual/input/input3
b43-phy2 ERROR: Firmware file "b43/b0g0initvals5.fw" not found
b43-phy2 ERROR: You must go to 
http://linuxwireless.org/en/users/Drivers/b43#devicefirmware and download the 
latest firmware (version 4).

Trying to do:

insmod b43
ifconfig wlan0 up

But the file most certainly exists:

r...@gw:~# ls -l /lib/firmware/b43/
-rw-r--r--    1 root     root           18 Jan 31 11:36 a0g0bsinitvals4.fw
-rw-r--r--    1 root     root          158 Jan 31 11:36 a0g0bsinitvals5.fw
-rw-r--r--    1 root     root          158 Jan 31 11:36 a0g0bsinitvals9.fw
...
-rw-r--r--    1 root     root          158 Jan 31 11:36 b0g0bsinitvals5.fw
...

My / (and therefor the above files) is on a USB key if that matters any.

Interestingly enough, there seem to be other occurrences of this this
issue:

http://forum.openwrt.org/viewtopic.php?id=18473
http://forum.openwrt.org/viewtopic.php?id=14233

The second one above is also a WL500gp and the problem for him only
occurred after moving his / to USB storage.

Is there some problem with the kernel trying to read firmware files from
a USB storage device perhaps?

Any ideas how to move forward with debugging this?

b.

P.S. I'm not terribly hopeful that this b43 driver will function well in
AP mode, but I thought it would be easy enough to give it a try.  I
guess not.  :-(

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