Nevermind, I am sure this is not the problem since the extensions get downloaded fine and the setup has been working for nearly two years now. Seen from tinycore the httplist script is just a text file, just that it's created dynamically from a directory listing. Here's the output:
# curl http://bootserver.local/tinycore/extensions.php
/tinycore/tce/Xlibs.tcz
/tinycore/tce/Xprogs.tcz
/tinycore/tce/Xvesa.tcz
/tinycore/tce/aterm.tcz
/tinycore/tce/fltk-1.1.10.tcz
/tinycore/tce/flwm_topside.tcz
/tinycore/tce/freetype.tcz
/tinycore/tce/imlib2-bin.tcz
/tinycore/tce/imlib2.tcz
/tinycore/tce/libICE.tcz
/tinycore/tce/libSM.tcz
/tinycore/tce/libX11.tcz
/tinycore/tce/libXau.tcz
/tinycore/tce/libXdmcp.tcz
/tinycore/tce/libXext.tcz
/tinycore/tce/libXfont.tcz
/tinycore/tce/libXi.tcz
/tinycore/tce/libXmu.tcz
/tinycore/tce/libXpm.tcz
/tinycore/tce/libXrandr.tcz
/tinycore/tce/libXrender.tcz
/tinycore/tce/libXt.tcz
/tinycore/tce/libfontenc.tcz
/tinycore/tce/libjpeg-turbo.tcz
/tinycore/tce/libpng.tcz
/tinycore/tce/libxcb.tcz
/tinycore/tce/wbar.tcz
The problem I am experiencing is the error message from the OP during boot, and a set of folders with strange permissions, mainly being not writeable by the 'tc' user or even belonging to 'root'. This includes /tmp/tce[/optional] and even /home/tc, so no user setting files can be written without correcting ownership/permissions beforehand. (Thinking about it, the mkdir error should be a consequence of /home/tc belonging to root.)
This is written from mind ATM, I can give more detail when I'm back at the office tomorrow.
Thanks again, Martin