Ok. I had the toplevel mozilla directory named a bit differently on the dev install path & the target . So it couldn't locate the component registry file components/xpti.dat on the target, & it would try to Autoregister the components on reboot. Making the target path match the dev install path exactly , cleared the autoregistering issue.
It still takes 1 second longer on the first run than the second run.. but thats for later..
 
The second big slowdown (now upto 7s) is a GetContentDOMWindow call
/embedding/browser/nsWebBrowser.cpp
nsWebBrowser::InitWindow()

   // Hook into the OnSecurirtyChange() notification for lock/unlock icon
   // updates
   nsCOMPtr<nsIDOMWindow> domWindow;
   rv = GetContentDOMWindow(getter_AddRefs(domWindow));
[digging]
 
"JacobZ" <[EMAIL PROTECTED]> wrote in message news:[EMAIL PROTECTED]...
In the first slowdown, 
  gtk_type_new() callsback gtk_moz_embed_new() , which calls EmbedPrivate::PushStartup() , which calls NS_InitEmbedding():
and NS_InitEmbedding() is what takes 5s on this system first run. [digging]
 
              ------     [in libgtkmozembed.so:gtkmozembed2.cpp] 
                            gtk_type_new (5.2 s)
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