Well just to follow up on this problem, it went away when I took out the
following from my mk.conf

COPTS+=-pipe -O

I'm not sure why it was causing EXT2FS to fail to build :(.

Out of da blue GuRU aka (guru@beastie.nscl.msu.edu) said:
> Hello folks,
> Is anyone else seeing a problem building a -current kernel with 
> "file-system EXT2FS" enabled?  My build keeps blowing up with the following
> error:
> 
> #   compile  BEASTIE/ext2fs_readwrite.o
> /usr/tools/bin/i386--netbsdelf-gcc -ffreestanding -g -pipe -O -Werror -Wall
> -Wno-main -Wno-format-zero-length -Wpointer-arith -Wmissing-prototypes
> -Wstrict-prototypes -Wno-sign-compare -fno-zero-initialized-in-bss -Di386 -I.
> -I/usr/src/sys/arch -I/usr/src/sys -nostdinc -DLKM -DNKMEMPAGES_MIN=33892
> -DKERNBASE_LOCORE=0xd0000000 -DIPSEC_DEBUG -DMAXUSERS=128 -D_KERNEL
> -D_KERNEL_OPT -c /usr/src/sys/ufs/ext2fs/ext2fs_readwrite.c
> 
> *** Failed target:  ext2fs_readwrite.o
> *** Failed command: echo '# ' "compile BEASTIE/ext2fs_readwrite.o"; echo
> /usr/tools/bin/i386--netbsdelf-gcc -ffreestanding -g -pipe -O -Werror -Wall
> -Wno-main -Wno-format-zero-length -Wpointer-arith -Wmissing-prototypes
> -Wstrict-prototypes -Wno-sign-compare -fno-zero-initialized-in-bss -Di386 -I.
> -I/usr/src/sys/arch -I/usr/src/sys -nostdinc -DLKM -DNKMEMPAGES_MIN="33892"
> -DKERNBASE_LOCORE="0xd0000000" -DIPSEC_DEBUG -DMAXUSERS=128 -D_KERNEL
> -D_KERNEL_OPT -c /usr/src/sys/ufs/ext2fs/ext2fs_readwrite.c;
> /usr/tools/bin/i386--netbsdelf-gcc -ffreestanding -g -pipe -O -Werror -Wall
> -Wno-main -Wno-format-zero-length -Wpointer-arith -Wmissing-prototypes
> -Wstrict-prototypes -Wno-sign-compare -fno-zero-initialized-in-bss -Di386 -I.
> -I/usr/src/sys/arch -I/usr/src/sys -nostdinc -DLKM -DNKMEMPAGES_MIN="33892"
> -DKERNBASE_LOCORE="0xd0000000" -DIPSEC_DEBUG -DMAXUSERS=128 -D_KERNEL
> -D_KERNEL_OPT -c /usr/src/sys/ufs/ext2fs/ext2fs_readwrite.c
> *** Error code 1
> 
> Stop.
> 
> Any pointers/hints will be well received :).
> 

#:D
-- 
guru <guru@beastie.nscl.msu.edu>       (,.)
http://www.msu.edu/~ikhala           \\\00 )
Driven by NetBSD                       \= )
                                       cc_|\_,^