OK Chris--I'm back up and in the saddle. I've downloaded and successfully compiled a generic WRT54G from source, uploaded and tested on the WRT54g!
. . so I'm making progress. Here is some feedback on the 1st two pages of your docs:
1) Setting up build system. . You reference a:
make menuconfig
This is the KERNEL configuration--you don't state what to do with this--any changes to the settings? Save as an alternative configuration?
I browsed through the various configurations, and it appears to be set up for cross-compiler, broadcom NICs, etc. So I assume you just exit and update the configuration there.
2) In BUILDING uClibc
rm WRT54G/tools/brcm/hndtools-mipsel-uclibc/lib/*.a\ WRT54G/tools/brcm/hndtools-mipsel-uclibc/lib/*.so*
I think you mean:
rm ~/WRT54G/tools/brcm/hndtools-mipsel-uclibc/lib/*.a
rm ~/WRT54G/tools/brcm/hndtools-mipsel-uclibc/lib/*.so*
and you state:
cd WRT54G/tools-src
and I think you mean:
cd ~/WRT54G/tools-src
. . . and the .bz2 version of that file is corrupt at that link--but the tar.gz is OK,
so here is the revised commands:
cd ~
wget http://uclibc.org/downloads/uClibc-0.9.26.tar.gz
cd ~/WRT54G
rm ~/WRT54G/tools/brcm/hndtools-mipsel-uclibc/lib/*.a
rm ~/WRT54G/tools/brcm/hndtools-mipsel-uclibc/lib/*.so*
rm -rf WRT54G/tools/brcm/hndtools-mipsel-uclibc/include
cd ~/WRT54G/tools-src
tar -xzvf ~/uClibc-0.9.26.tar.gz
cd uClibc-0.9.26
cp ~/wrt54g/uclibc/.config .config
patch -sp1 < ~/wrt54g/uclibc/uclibc-wrt54g.diff
make CROSS=mipsel-uclibc- all
make CROSS=mipsel-uclibc-\
RUNTIME_PREFIX=/opt/brcm/hndtools-mipsel-clibc/ install
I then get the following error when doing the "make CROSS=mipsel-uclibc- all"
The file /home/cm/WRT54G/release/src/linux/linux/Makefile is missing!
Perhaps your kernel source is broken?
make: *** [headers] Error 1
I then looked at ~/wrt54g/uclibc/.config from your source subversion--it has a reference to /home/cm:
KERNEL_SOURCE="/home/cm/WRT54G/release/src/linux/linux"
So I changed it to this:
KERNEL_SOURCE="~/wrt54g/release/src/linux/linux"
Now I get a different error:
Manuel's hidden warnings (UCLIBC_MJN3_ONLY) [N/y/?] n
+ ./extra/scripts/fix_includes.sh -k '~/WRT54G/release/src/linux/linux' -t mips
The file ~/WRT54G/release/src/linux/linux/Makefile is missing!
Perhaps your kernel source is broken?
make: *** [headers] Error 1
I have a Makefile in this path. . . (I 'ls'ed from a cut/paste of this message, and edited the file--it looks good).
Any ideas where to go from here?

I believe you can't use '~' c
I believe you can't use '~' characters in the KERNEL_SOURCE path, but you can use $(HOME) instead.
The .tar.bz2 version works fine for me.
Followup
When I change to
~/WRT54G/tools-src/uclibc
instead of
~/WRT54G/tools-src/uClibc-0.9.26
and do the
make CROSS=mipsel-uclibc- all
It appears to make. . . Is the path incorrect in the documentation?
. . . or--do we even need to download it for the 3.x version of the source library--do they (Linksys) already include it. . .
Woops--when I do the next command, and hit enter, it just generates 95% utilization for hours, never does anything. . .
make CROSS=mipsel-uclibc- RUNTIME_PREFIX=/opt/brcm/hndtools-mipsel-uclibc/ install
OK--stuck. Any help anyone may offer would be appreciated. Thanks.
No, you shouldn't be using to
No, you shouldn't be using tools-src/uclibc instead of tools-src/uClibc-0.9.26