I did more debugging on this last night, and found an
if statement that made no sense at all to me. It is
checking to see if an old section needs to be moved
because it came after the point where the new section
was inserted, and the if test is first rounding up
the old section file offset. Huh? The old section
either started after the new section or it didn't.
What on earth does rounding the offset up accomplish
other than failing to move a section that should
have been moved? (which is what happened to me :-).
Even if rounding makes sense for some reason I
can't understand, it is using the alignment
requirement from the old bss section to round
this completely different section which may have
a completely different alignment requirement.
Again, Huh?. Anyway, the only reason the old code
worked was because it was a different size
so the file layout happened to be one that worked
despite the silly logic.

I'm attaching (because outlook persistently screws
up line wrapping :-) a text file with all the
analysis showing what happened and the patch
I applied to unexelf.c which made it work for
me.