After spending the day tweaking various aspects of my new box, and trying different kernel options, I discovered the cause of my problem as originally posted. I booted with the stock huge kernel and then saved a copy of dmesg. I then booted with my recompiled kernel and saved that dmesg. I noticed two interesting differences:
stock huge kernel:
Console: switching to colour frame buffer device 100x37
fb0: VESA VGA frame buffer device
my custom kernel:
fb1: VESA VGA frame buffer device
I then used Kompare to diff the stock huge kernel config file with my config file. I found two suspects:
stock huge kernel:
CONFIG_FB_DDC=m
CONFIG_FB_NVIDIA=m
my custom kernel:
CONFIG_FB_DDC=y
CONFIG_FB_NVIDIA=y
I modified my kernel for module support. The kernel then booted with an expected normal screen and fat penguins.
I don't pretend to understand the underlying root cause, although I am using the on-board nvidia video chip rather than a separate nvidia video card.
During my journey this afternoon, I ran across a thread about using both cores of a dual core processor to speed compile times. I use a script I wrote to automate most of my compiling and I added "-j4" to my make commands. Watching gkrellm told me that both CPU cores finally were being used. My compile time went from a half hour (a dramatic improvement over my 3+ hours with my old box) to about 15 minutes. Sweet.
I noticed a kernel option called CONFIG_NR_CPUS and the default is 32. I changed that to 2 as that is all the cores in my BE-2400 CPU. I don't know whether that will make any difference anywhere.
I noticed an option to modify the console scroll buffer (CONFIG_VGACON_SOFT_SCROLLBACK_SIZE). I changed that option from the default of 64KB to 256KB.
I hope this information helps future inquiries.
Question:
In my rc.modules script I enabled the modprobe acpi-cpufreq option. I always receive an error message of
FATAL: Error inserting acpi_cpufreq (/lib/modules/2.6.21.5/kernel/arch/i386/cpu/cpufreq/acpi-cpufreq.ko) no such device. The module does exist. I modified the CPU type in my kernel configuration from the stock huge kernel Pentium Pro to MK8, as my CPU is a member of the K8 family (BE-2400). I still receive this error message. Any help is appreciated.