The idea

Use only as much space as necessary. This includes no portage nor gcc install on target system (ipaq). The idea is to fully cross-compile the system for ipaq on a i686 host into a subdir (using the ${ROOT} portage feature) and create a jffs2 image which will be uploaded to the ipaq (leter updates will be done over nfs-mounted root).

The steps

It's best if you write this to a script or so...

emerge crossdev

crossdev --target arm-unknown-linux-gnu

export ARCH="arm"
export ACCEPT_KEYWORDS="arm"
export CHOST="arm-unknown-linux-gnu"
export CBUILD="i686-pc-linux-gnu"

export CFLAGS="-O2 -pipe"
export CXXFLAGS=${CFLAGS}

export ROOT="/tmp/ipaq"

export USE="-*"

export FEATURES="-distcc"

export CONFIG_PROTECT="-* ${ROOT}/etc"

### Bootstrap ###
USE="bootstrap build" emerge sysvinit
USE="bootstrap build" emerge baselayout
emerge sys-kernel/linux-headers
USE="bootstrap build" emerge sys-libs/glibc