Hi
Ok after going out for a few hours and coming back I have some progress.
Curaga and I are both right. It seems it is *both* the xf86-intel driver version and the mesa version that are the problem(s) with glxgears.
I compiled xf86-video-intel-2.5.1, quit X, replaced the intel drivers in Curaga's Xorg and restarted. (2.5.0 would not compile).
Now glxinfo and glxgears do not crash (yay) but still give the "Failed to initialize TTM buffer manager. Falling back to classic." message but no errors. But it runs.
glxgears give a framerate of 60 fps - this is because Intel drivers now tie the frame rate to the screen refresh rate by default with vsync, this is not a benchmark. But it shows 3D and dri are working.
OpenGL version string: 1.4 Mesa 7.2.
Mesa version 7.2 does not support GEM. We need mesa >= 7.3 See the useful
http://bugs.gentoo.org/show_bug.cgi?id=237468 which also suggests use 2.6.1 as the minimum intel driver version. GEM support was still wobbly with 2.5.0 and presumably 2.5.1.
We may(?) need care in selecting which driver versions to build. There are suggestions that the most recent Intel drivers only work with the most recent kernel, though I do not know if this is correct. But this might explain why the 2.7.0 Intel driver in the extension does not work for glxgears/glxinfo so I think it is likely, unless mesa 7.2 somehow borks that driver.
So we will need a rebuild of Xorg with updated mesa and possibly the Intel driver version that plays nicely with our kernel.
EDIT: if someone wants to build Xorg with updated mesa I will be happy to experiment with intel driver versions to find the latest one that will work if need be.