It appears that while booting maybe 1/2 the time piCore doesn't assemble the overlay file system correctly. The symptom is that some important file is missing. Sometimes it is a driver, sometimes it is a library or something else. When I examine the system, the tcz files are mounted on /tmp/tcloop, but the simlink from the ultimate location if at least one of the files contained in a tcz is missing. Looking back at some of the previous problems I had, this could explain all. Recall that I needed to add two font directories to /usr/local/lib/X11/fonts. Adding them with the filetool mechanism did not work. Adding them to Xorg-fonts.tcz did not work. What finally did work was to copy the directories to /opt, and then create the simlinks in bootsync.sh. I now suspect that this worked as all the init scripts have finished by the time bootsync.sh runs.
Here is the contents of my /tmp/tcloop:/tmp/tcloop$ ls
Xorg/ libXdamage/ libxcb/
Xorg-fonts/ libXdmcp/ libxkbfile/
busybox-httpd/ libXext/ libxshmfence/
bzip2-lib/ libXfixes/ mesa/
ca-certificates/ libXfont2/ mtdev/
expat2/ libXxf86vm/ ncurses/
freetype/ libdrm/ openssh/
gamin/ libelf/ openssl/
gcc_libs/ libepoxy/ pcre/
glib2/ libevdev/ pixman/
graphite2/ libfontenc/ xf86-input-libinput/
harfbuzz/ libinput/ xf86-video-fbturbo/
inetutils-servers/ libpciaccess/ xkbcomp/
libX11/ libpng/ xkeyboard-config/
libXau/ libudev/ xorg-server/
And the contents of my /mnt/mmcblk0p2/tce/onboot.lst:cat /mnt/mmcblk0p2/tce/onboot.lst
openssh.tcz
Xorg.tcz
busybox-httpd.tcz
inetutils-servers.tcz
I removed Xprogs.tcz from the list of dependencies in Xorg.tcz.dep. This made the above list somewhat shorter than by default.
The contents of .filetool.lst is the default.
This behavior is intermittent. Sometime piCore completes correctly, sometime it will miss some file. As far as I know, there are no external asynchronous processes that could affect the init scripts. Any hints as to what might be going on are welcome.