I noticed that whwn I build from the cupcake branch, the browser
crashes immediately, because the bad armv5 gears.so is present in
/data/data/com.android.browser/app_plugins/. I don't have this problem
when I install the 1.5 alpha version. Are all the Koolu changes in the
public tree?

In any case, I decided to try to build a good gears.so for Freerunner.
It worked, and I know have GMail and Google Calendar working offline
in the browser!

Here's the procedure I followed:

* Checkout Gears source with SVN:
    svn checkout http://gears.googlecode.com/svn/trunk/ gears-read-only

* Change into the gears directory:
    cd gears-read-only/

* Update the tree to version or the binary on the cupcake branch, 0.5.17.0
    svn -r 3291 update

* Patch config.mk as follows:
Index: gears/tools/config.mk
===================================================================
--- gears/tools/config.mk       (revision 3291)
+++ gears/tools/config.mk       (working copy)
@@ -427,15 +427,16 @@
 HTML_LOCALE    = en-US

 COMPILE_FLAGS_dbg += \
-               -g -O \
-               -march=armv5te -mtune=xscale -mthumb-interwork \
+    -march=armv4t -mtune=arm920t -msoft-float -mthumb-interwork \
+               -D__ARM_ARCH_4__ -D__ARM_ARCH_4T__              -g -O \
                -funwind-tables -mapcs-frame \
                -ffunction-sections -fdata-sections \
                $(NULL)

 COMPILE_FLAGS_opt += \
                -O2 \
-               -march=armv5te -mtune=xscale -mthumb-interwork -mthumb \
+    -march=armv4t -mtune=arm920t -msoft-float -mthumb-interwork \
+               -D__ARM_ARCH_4__ -D__ARM_ARCH_4T__              -g -O \
                -fomit-frame-pointer \
                -ffunction-sections -fdata-sections \
                $(NULL)

* Setup the environment
export ANDROID_BUILD_TOP=/home/jim/projects/mydroid-cupcake/
export 
ANDROID_TOOLCHAIN=$ANDROID_BUILD_TOP/prebuilt/linux-x86/toolchain/armv4t-android-eabi-4.2.1/bin/
export ANDROID_PRODUCT_OUT=$ANDROID_BUILD_TOP/out/target/product/freerunner/

* Build
cd gears/
make OS=android MODE=opt

* The build creates
gears/gears/bin-opt/installers/gears-android-opt-0.5.17.0.zip I
extracted gears.so from there and used adb to copy it to
/data/data/com.android.browser/app_plugins/ on my FR. After
restarting, the browser doesn't crash, and prompts for permission to
use Gears when I go to sites that use it.

Hope this helps!

Jim
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