I've compiled OpenWRT from git and generated image for my WNDR4500 with:
$(call Image/Build/Chk,$(1),wndr4500,U12H189T00_NETGEAR,1,$(patsubst
jffs2-%,jffs2,$(1)))

1) Official upgrades seem to work, I've successfully upgraded 1.0.0.58
to 1.0.0.103.

2) Installing openwrt-wndr4500-squashfs.chk using stock (official)
firmware GUI partially-failed with:
Writing 2756608 bytes to /dev/mtd15.
......................mtd ioctl MEMERASE error.
See 1.upgrade.txt for details.

3) I've tried re-installing same image using tftp. I've used CFE
bootloader, executed "tfptd" and then uploaded image from my notebook.
It looks it succeed:
Reading :: Done. 2756666 bytes read
Programming...done. 2756666 bytes written
Write len/chksum offset @ 0x00EFFFF8...done.
However I'm still getting the same boot freeze. See 2.tftp.txt for details.

Any tips on that?

-- 
Rafał
fileSize = 2756666
..........................................killall: bftpd: no process killed
killall: smbd: no process killed
killall: nmbd: no process killed
killall: ntfs-3g: no process killed

Writing 2756608 bytes to /dev/mtd15.
......................mtd ioctl MEMERASE error.
Doing nvram commit by pid 2154 !
Restarting system.
Decompressing...done


CFE for WNDR4500 version: v1.0.3
Build Date: Thu Jul 21 19:28:03 CST 2011 
Init Arena
Init Devs.
Boot partition size = 262144(0x40000)
Found an ST compatible serial flash with 32 64KB blocks; total size 2MB
Found a Samsung NAND flash with 2048B pages or 128KB blocks; total size 128MB
et0: Broadcom BCM47XX 10/100/1000 Mbps Ethernet Controller 5.100.138
CPU type 0x19749: 600MHz
Tot mem: 131072 KBytes

Device eth0:  hwaddr <OMMITED>, ipaddr 192.168.1.1, mask 255.255.255.0
        gateway not set, nameserver not set
Checking crc...Loader:raw Filesys:raw Dev:nflash0.os File: Options:(null)
Loading: .. 3780 bytes read
Entry at 0x80001000
Closing network.
Starting program at 0x80001000
Decompressing...done


CFE for WNDR4500 version: v1.0.3
Build Date: Thu Jul 21 19:28:03 CST 2011
Init Arena
Init Devs.
Boot partition size = 262144(0x40000)
Found an ST compatible serial flash with 32 64KB blocks; total size 2MB
Found a Samsung NAND flash with 2048B pages or 128KB blocks; total size 128MB
et0: Broadcom BCM47XX 10/100/1000 Mbps Ethernet Controller 5.100.138
CPU type 0x19749: 600MHz
Tot mem: 131072 KBytes

Device eth0:  hwaddr <OMMITED>, ipaddr 192.168.1.1, mask 255.255.255.0
        gateway not set, nameserver not set
Startup canceled
CFE> ^C
CFE> ^C
CFE> tftpd
Start TFTP server
Reading :: Done. 2756666 bytes read
Programming...done. 2756666 bytes written
Write len/chksum offset @ 0x00EFFFF8...done.
Decompressing...done


CFE for WNDR4500 version: v1.0.3
Build Date: Thu Jul 21 19:28:03 CST 2011
Init Arena
Init Devs.
Boot partition size = 262144(0x40000)
Found an ST compatible serial flash with 32 64KB blocks; total size 2MB
Found a Samsung NAND flash with 2048B pages or 128KB blocks; total size 128MB
et0: Broadcom BCM47XX 10/100/1000 Mbps Ethernet Controller 5.100.138
CPU type 0x19749: 600MHz
Tot mem: 131072 KBytes

Device eth0:  hwaddr <OMMITED>, ipaddr 192.168.1.1, mask 255.255.255.0
        gateway not set, nameserver not set
Checking crc...Loader:raw Filesys:raw Dev:nflash0.os File: Options:(null)
Loading: .. 3780 bytes read
Entry at 0x80001000
Closing network.
Starting program at 0x80001000
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