Hi!

I think I have a big problem with my wifi-card. I tried to boot with the original firmware from Netgear an with the prebuild image file "openwrt-wgt634u-2.6-squashfs.bin" from the download archive.

I'm logging the complete boot-up process via serial console and I get the following message during the wireless setup:

Netgear-firmware first: (wgt634u_1_4_1_9.img)

wlan - Using /lib/modules/wlan.o
wlan: 0.7.2.0 BETA
ath_hal - Using /lib/modules/ath_hal.o
Warning: loading ath_hal will taint the kernel: non-GPL license - Proprietary
  See http://www.tux.org/lkml/#export-tainted for information about tainted modu
les
ath_hal: 0.9.6.1
ath_pci - Using /lib/modules/ath_pci.o
ath_pci: 0.8.4.0 BETA
PCI: Enabling device 01:01.0 (0000 -> 0002)
ath_pci: cache line size not set; forcing 8
Data bus error, epc == c00b62b4, ra == c00bd92c
Oops in traps.c::do_be, line 492:
$0 : 00000000 1000fc00 c00f3000 00004000 80324000 c00ccb08 00008000 00008000
$8 : 00000001 99999999 80e19854 80e19868 8023278b fffffffb 0000000a 8021fcb8
$16: c00b627c 00008000 80324000 c00cfb64 80324000 c00eb000 80e10000 8021fc80
$24: ffffffff 00000000                   8021e000 8021fc50 8021fc88 c00bd92c
Hi : 000003e7
Lo : 6cb48000
epc  : c00b62b4    Tainted: P
Status: 1000fc03
Cause : 0000001c
Process insmod (pid: 901, stackpage=8021e000)
Stack:    00000000 00000001 00000000 00000001 c00b627c c00bd92c 8024e0c0
c00d0a5c c00d0a80 c00d0a2c c00c4758 80324000 00008000 00009820 00000000
00000000 55555555 aaaaaaaa 66666666 99999999 00000000 00000013 c00b627c
00000013 80324000 c00cfb64 00000000 c00eb000 80e10000 8021fd50 00000007
c00bd1e8 00000000 c00cfb74 c00cfb64 80e10000 00000000 c00eb000 80e10000
40010000 ...
Call Trace:   [<c00b627c>] [<c00bd92c>] [<c00d0a5c>] [<c00d0a80>] [<c00d0a2c>]
[<c00c4758>] [<c00b627c>] [<c00cfb64>] [<c00bd1e8>] [<c00cfb74>] [<c00cfb64>]
[<c00b66f8>] [<80170ea8>] [<c00b6080>] [<800e0e80>] [<c00d8420>] [<c00d81c8>]
[<800323d8>] [<80032948>] [<8000528c>] [<8002f190>] [<c00d8f68>] [<80004b78>]
[<c00e8ea8>] [<c00e6dfc>] [<c00e6d68>] [<c00e8ea8>] [<c00e8f1c>] [<800e0980>]
[<c00e8f1c>] [<800e0a60>] [<c00e8a8e>] [<8001378c>] [<c00e8f1c>] [<8001378c>]
[<c00e8f1c>] [<c00e7068>] [<c00e7058>] [<c00e8a84>] [<c00e8a6c>] ...

Code: 00801021  8c420014  00471021 <8c500000> 15000005  02003821  3c02c00b  2442
6164  0040f809
Segmentation fault
slhc - Using /lib/modules/slhc.o

and openwrt-image: (openwrt-wgt634u-2.6-squashfs.bin)

ath_hal: module license 'Proprietary' taints kernel.
ath_hal: 0.9.30.13 (AR5210, AR5211, AR5212, AR5416, RF5111, RF5112, RF2413, RF54
13, RF2133, REGOPS_FUNC)
ath_rate_minstrel: Minstrel automatic rate control algorithm 1.2 (svn r2568)
ath_rate_minstrel: look around rate set to 10%
ath_rate_minstrel: EWMA rolloff level set to 75%
ath_rate_minstrel: max segment size in the mrr set to 6000 us
wlan: mac acl policy registered
ath_pci: 0.9.4.5 (svn r2568)
PCI: Enabling device 0000:00:01.0 (0000 -> 0002)
PCI: Fixing up device 0000:00:01.0
Data bus error, epc == c012a01c, ra == c0140bd0
Oops[#1]:
Cpu 0
$ 0   : 00000000 1000b800 c00a8004 c012a000
$ 4   : 81e70000 00008004 00000000 00000000
$ 8   : c015dc09 c015dc08 00000010 00000000
$12   : 00000000 00000000 80278d04 00000000
$16   : 00000028 81e70000 c012a014 c012a000
$20   : fffcffff c012a028 00010000 8002b0bc
$24   : 00000010 800ff0a0
$28   : 813ec000 813edb80 00000138 c0140bd0
Hi    : 000003e1
Lo    : 47b8c000
epc   : c012a01c     Tainted: P
ra    : c0140bd0 Status: 1000b803    KERNEL EXL IE
Cause : 0000001c
PrId  : 00029007
Modules linked in: ath_pci wlan_xauth wlan_wep wlan_tkip wlan_ccmp wlan_acl ath_
rate_minstrel ath_hal(P) wlan_scan_sta wlan_scan_ap wlan ppp_async ppp_generic s
lhc crc_ccitt switch_robo switch_core diag
Process insmod (pid: 364, threadinfo=813ec000, task=813f4c00)
Stack : 10009800 80028f3c 00000000 00000080 00000001 00000000 81e70000 00000000
        81e70000 81e70000 813edcd4 c0140d9c 00000000 81e70000 ffffffff 00000000
        00000000 81e70000 00000001 c01435f8 c00a0000 813ee000 813edcd4 8002b0bc
        00000013 c00a0000 00000000 c0142e1c 81e70000 813ee000 813edcd4 c0140d9c
        00000013 c00a0000 81e70000 00000000 81e70000 813ee000 c013ce14 c013cda4
        ...
Call Trace:[<80028f3c>][<c0140d9c>][<c01435f8>][<8002b0bc>][<c0142e1c>][<c0140d9
c>][<c013ce14>][<c013cda4>][<800b6294>][<80028b3c>][<c012a710>][<801088a4>][<c01
2a2a4>][<80028b3c>][<c00e4fd0>][<80048bb0>][<8000e6a8>][<8005aab4>][<c00ea994>][
<80048cc4>][<80048c90>][<8002b0bc>][<c00ee384>][<80127fd8>][<8010ed2c>][<8012c2a
4>][<801f7f5c>][<800bd85c>][<8012c714>][<8012af2c>][<800f9570>][<8012c5ac>][<801
2b098>][<8002b0bc>][<8012b4b8>][<80023454>][<8010ef44>][<80023454>][<c006d054>][
<80047898>][<8000bc60>]

Code: 00000000  8c820014  00451021 <8c420000> 03e00008  00000000  3c020010  3442
624e  70822002
eth0.1: add 01:00:5e:00:00:01 mcast address to master interface

This happens everytime I try to boot the router (well.. now at least). At first there was nothing. Not even
a detected controller at the pci-bus.
Now it seems to work (in a way) and the network controller ist getting quite warm, but not as hot as the CPU. I think that ist ok.
(I tried to clean the pins with a rubber to get a better connection and it had some effect.)

But do you have any idea what could be going wrong now? Maybe some serious hardware defect?
Unfortunately I'm not that familiar with crosscompiling so it would be very difficult for me to get another kamikaze version
to run on the wgt. Do you have any suggestions what I could try with the prebuilt image I already have?