Building the AVR toolchain by hand also thwarted me somewhere in the building of the avr-binutils package — it doesn’t want to build on my Mac. As soon as I entered the dependency hell of installing an upgraded gcc to build binutils and that didn’t work either, I got pretty fed up with that line of attack. Finally, I tried installing the AVR toolchain from the Fink project. Success! Here are the steps it took to get it up and running…
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I’ve been using fink to keep my AVR packages up to date for about six years. I highly recommend it to other OS/X hardware hackers. Also use the EDA tools offered by fink (gschem, pcb, and gerbv) even some PIC tools are available. I used to be more active about patching and updating the fink files, but that seems to be all taken care of these days.