> > Disk space and Inodes are available... this is a fresh installation.
>
> It's one or the other.
-:[/]#> df -h
Dateisystem          Größe Benut  Verf Ben% Eingehängt auf
/dev/md/3             9,6G  1,8G  7,8G  19% /
sysfs                 9,6G  1,8G  7,8G  19% /sys
udev                  9,6G  1,8G  7,8G  19% /dev
devpts                9,6G  1,8G  7,8G  19% /dev/pts
shm                   9,6G  1,8G  7,8G  19% /dev/shm

-:[/]#> df -i
Dateisystem           INodes  IBenut.  IFrei IBen% Eingehängt auf
/dev/md/3            1500000  223632 1276368   15% /
sysfs                1500000  223632 1276368   15% /sys
udev                 1500000  223632 1276368   15% /dev
devpts               1500000  223632 1276368   15% /dev/pts
shm                  1500000  223632 1276368   15% /dev/shm

> I do recall an incident where someone used non-standard compiler flags to
> build Courier, resulting in an incompatible ABI with glibc that resulted in
> similar symptoms.
Thanks for the hint. 
I now copied the CFLAGS from another - working - system and compiled courier 
again, but no luck.

> How did you build Courier?

CFLAGS="-Os -march=k8 -pipe -funroll-loops -fomit-frame-pointer -msse -msse 
-m3dnow"
CHOST="i686-pc-linux-gnu"
CXXFLAGS="${CFLAGS}"

-:[/]#> gcc -v
Es werden eingebaute Spezifikationen verwendet.
Ziel: i686-pc-linux-gnu
Konfiguriert 
mit: /var/tmp/portage/gcc-4.1.1-r1/work/gcc-4.1.1/configure --prefix=/usr 
--bindir=/usr/i686-pc-linux-gnu/gcc-bin/4.1.1 
--includedir=/usr/lib/gcc/i686-pc-linux-gnu/4.1.1/include 
--datadir=/usr/share/gcc-data/i686-pc-linux-gnu/4.1.1 
--mandir=/usr/share/gcc-data/i686-pc-linux-gnu/4.1.1/man 
--infodir=/usr/share/gcc-data/i686-pc-linux-gnu/4.1.1/info 
--with-gxx-include-dir=/usr/lib/gcc/i686-pc-linux-gnu/4.1.1/include/g++-v4 
--host=i686-pc-linux-gnu --build=i686-pc-linux-gnu --disable-altivec 
--enable-nls --without-included-gettext --with-system-zlib --disable-checking 
--disable-werror --enable-secureplt --disable-libunwind-exceptions 
--disable-multilib --disable-libmudflap --disable-libssp --disable-libgcj 
--enable-languages=c,c++ --enable-shared --enable-threads=posix 
--enable-__cxa_atexit --enable-clocale=gnu
Thread-Modell: posix
gcc-Version 4.1.1 (Gentoo 4.1.1-r1)

Thanks,

Manuel
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