As original creator of this thread, I followed the process described below.
I confirm that the original problem I reported has been resolved;
sage 5.0 is now usable for my projects.

Thank you Dima and all of the other team members who contributed to this 
solution!
Jim Clark

On May 19, 2012, at 6:16 AM, Dima Pasechnik wrote:

> here is a fix:
> in SAGE_ROOT (the directiry where Sage startup script, called sage, is), run
> ./sage -f 
> http://boxen.math.washington.edu/home/jdemeyer/spkg/mpir-2.4.0.p4.spkg
> this will install a patched MPIR  spkg.
> Then run
> ./sage -b
> to rebuild parts of Sage which depend upon MPIR (it takes a while, perhaps 15 
> minutes or so).
> 
> After this, Sage works as it should. The problem appears to be due to Core2 
> processors 
> (e.g. in some Macbooks Air) being unable to run certain instructions that 
> they are expected to run, and so
> an executable built on a "better" processor is unaware of this.
>  
> 
> On Thursday, 17 May 2012 01:11:05 UTC+2, Jim wrote:
> Hello sage team. 
> 
> I have just downloaded and installed Sage 5.0 on my system: 
> 
> Mac OS X 10.6.8 
> 
> I downloaded sage-5.0-OSX-64bit-10.6-x86_64-Darwin.dmg. 
> 
> It keeps crashing and is unusable. 
> 
> Here is a simple session: 
> 
> ---------------------------------------------------------------------- 
> | Sage Version 5.0, Release Date: 2012-05-14                         | 
> | Type notebook() for the GUI, and license() for information.        | 
> ---------------------------------------------------------------------- 
> sage: # Feather parameters 
> sage: L_lv = 1300    # length of leading vane in microns 
> sage: L_tv = 2300    # length of trailing vane 
> sage: L_tot = L_lv + L_tv 
> sage: shaft_cenx = L_lv  # center of shaft 
> sage: shaft_ceny = 0 
> sage: R_shaft = 185  # radius of shaft 
> sage: dx = 10        # nominal spacing between grid points 
> sage: T_v1 = 10      # thickness of vane at edge 
> sage: T_v2 = 20      # thickness near center 
> sage: L_planar_lv = int(L_lv * .75)    # length of planar segment of vane 
> 
> ------------------------------------------------------------------------ 
> Unhandled SIGILL: An illegal instruction occurred in Sage. 
> This probably occurred because a *compiled* component of Sage has a bug 
> in it and is not properly wrapped with sig_on(), sig_off(). You might 
> want to run Sage under gdb with 'sage -gdb' to debug this. 
> Sage will now terminate. 
> ------------------------------------------------------------------------ 
> /Applications/sage/spkg/bin/sage: line 312:  1513 Illegal instruction     
> sage-ipython "$@" -i 
> logout 

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