Upgrade 7.0 to 7.2 installworld failed

[Colin]

Hi folks,
I have started trying to upgrade my 7.0 to 7.2 and it all seemed to be 
going well until I got to installworld.

First off I did a cvsup for src-all from cvsup.ie.freebsd.org with the 
tag RELENG_7_2

I have then done:

cd /usr/src
make buildworld
make kernel-toolchain
make -DALWAYS_CHECK_MAKE buildkernel KERNCONF=TED
make -DALWAYS_CHECK_MAKE installkernel KERNCONF=TED
shutdown -r now
mergemaster -p
make installworld

installworld goes through Making hierarchy fine then gets to Installing 
everything and goes:


 >>> Installing everything
--------------------------------------------------------------
cd /usr/src; make -f Makefile.inc1 install
===> share/info (install)
===> lib (install)
===> lib/csu/i386-elf (install)
cc -O2 -fno-strict-aliasing -pipe  -I/usr/src/lib/csu/i386-elf/../common 
  -I/usr/src/lib/csu/i386-elf/../../libc/include -Wsystem-headers -Wall 
-Wno-format-y2k -W -Wno-unused-parameter -Wstrict-prototypes 
-Wmissing-prototypes -Wpointer-arith -Wreturn-type -Wcast-qual 
-Wwrite-strings -Wswitch -Wshadow -Wcast-align -Wunused-parameter 
-Wchar-subscripts -Winline -Wnested-externs -Wredundant-decls 
-Wno-pointer-sign -c /usr/src/lib/csu/i386-elf/crt1.c
/usr/src/lib/csu/i386-elf/crt1.c:33:20: error: stdlib.h: No such file or 
directory
In file included from /usr/src/lib/csu/i386-elf/crt1.c:35:
/usr/src/lib/csu/i386-elf/../../libc/include/libc_private.h:184:24: 
error: sys/_types.h: No such file or directory

(Full output at http://www.pastebin.org/68429 )

Both the .h files referenced are in the /usr/src directory

ted# find ./ -name stdlib.h
./cddl/compat/opensolaris/include/stdlib.h
./contrib/bind9/lib/isc/include/isc/stdlib.h
./contrib/bind9/lib/lwres/include/lwres/stdlib.h
./contrib/libstdc++/include/c_compatibility/stdlib.h
./contrib/libstdc++/include/tr1/stdlib.h
./include/stdlib.h

ted# find ./ -name _types.h
./sys/amd64/include/_types.h
./sys/arm/include/_types.h
./sys/i386/include/_types.h
./sys/ia64/include/_types.h
./sys/pc98/include/_types.h
./sys/powerpc/include/_types.h
./sys/sparc64/include/_types.h
./sys/sun4v/include/_types.h
./sys/sys/_types.h

So I did some looking around, someone recommended removing the src 
folders and pulling a fresh copy for someone else that had the same 
problem. I did this to no joy.

So, the only thing that I'm left with is the custom kernel, I haven't 
tried generic as I don't want to be left running with a server and no 
firewall. I am doing this all remotely by SSH so no single user mode.

My kernel conf file is here:

http://www.pastebin.org/68430

I went through the new GENERIC that came down with the cvsup and pulled 
in most of the options and disabled the same devices as with my 7.0 kernel.

So can anyone see something I'm missing in the kernel or is there 
another solution I'm missing?

Thanks,
Colin.