maybe you should put /tmp on sd till you get your microdrive reliably automounting?
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I fixed it by moving /etc/rc.d/init.d/pcmcia, which sets up the cf drivers on the Z, to /etc/rc.d/rc.pcmcia and removing the symlink /etc/rc.d/rc5.d/S05pcmcia. Then in /etc/rc.d/rc.sysinit, I put a call to rc.pcmcia right before local file systems are mounted like so:
. /etc/rc.d/rc.pcmcia start
action "Mounting local FS:" mount -a -t nonfs
#action "Mounting remote FS:" mount -a -t nfs
Since I have an entry in /etc/fstab for my microdrive, it gets mounted by the second line above, and this allows me to maintain the link /tmp -> /mnt/cf/tmp. /var is another matter. The pcmcia script makes heavy use of /var, and I was unwilling to study the problem of removing the dependency, or risk just mounting on top of it. But now the logs have the full 1MB to play with.
It's cool that syslog is running on this ROM. It's very helpful for debugging problems and learning about the details of the startup. However it won't do to keep that in production, since it would fill up quickly.
Next up, why doesn't the qpe package manager work for non root targets?
I'm willing to host a Wiki, BTW. It would be a complement to these forums, not a replacement.