George C wrote on Wed, Dec 27, 2006 at 04:53:43PM -0500:

> I had a 4.0-release install right from the cd pack.

That's fine, indeed.  :-)

> I extracted the source from the cd and then updated it to -current
> (both /usr/src and /usr/src/sys).  then i built the new kernel,

This is not the safest road to -current.  Better get a snapshot and
use the standard install or upgrade process before you try to
compile a -current system.

> reboot, and was going to build the userland when i ran into the
> bnx firmware problem.

Well, that is about the reason why large jumps forward are more
easily done by binary than by source upgrades:

 $ tar -tzvf 4.0-release/i386/base40.tgz | grep bnx | cut -b56-
./usr/libdata/perl5/site_perl/i386-openbsd/dev/pci/if_bnxreg.ph
 $ tar -tzvf 4.0-current/i386/base40.tgz | grep bnx | cut -b56-     
./etc/firmware/bnx
./etc/firmware/bnx-license
./usr/libdata/perl5/site_perl/i386-openbsd/dev/pci/if_bnxreg.ph

If you try to compile a new system, you always run a risk that
some part of the task turns out to be non-trivial because something
changed in between.  The risk increases with time, and going from
4.0-release to 4.0-current in one step proved more difficult than
you liked.

The FAQ section 5.3.4 you cite is certainly important, yet you
should not overlook section 5.3.2, either:
  http://www.openbsd.org/faq/faq5.html#BldBinary

[...]
>   init: not found
>   panic: no init

Ooops.  That's bad.  Apparently, you trashed /sbin, and quite
possibly more besides.

Do not try to repair that system, at very best, it will result
in a waste of time.

Reconsider whether you actually need -current.  If you are not
quite sure, use -stable instead.

In case you are really sure you want -current, use the latest
snapshot - and stay with that, if you can.  See FAQ 5.2:
  http://www.openbsd.org/faq/faq5.html#WhySrc
When you feel the need to upgrade, get the next snapshot.

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