Per the 'Debian Linux Kernel Handbook' chapter 'Common kernel-related
tasks' 
(http://kernel-handbook.alioth.debian.org/ch-common-tasks.html#s-common-official)
I tried:

make KDEB_PKGVERSION=1.0_xxx deb-pkg 

and the build went OK until the final step(s) to produce the 
image .deb file:

dpkg-deb: building package `linux-headers-3.2.12' in
`../linux-headers-3.2.12_1.0-interatom_i386.deb'.
dpkg-deb: building package `linux-libc-dev' in
`../linux-libc-dev_1.0-interatom_i386.deb'.
dpkg-deb: building package `linux-image-3.2.12' in
`../linux-image-3.2.12_1.0-interatom_i386.deb'.
dpkg-deb (subprocess): data member: internal gzip write error: 'No space
left on device'
dpkg-deb: error: subprocess <compress> from tar -cf returned error exit
status 2
make[1]: *** [deb-pkg] Error 2
make: *** [deb-pkg] Error 2
Command exited with non-zero status 2

This was the first time I tried this method, I've been using 
make-kpkg for years without a problem.  Like the OP, my /tmp
size was low, 200 megabytes to be precise.  The 200M was derived from
the value of '/etc/default/tmpfs' as 20% of RAM, but that value used to
be 50% IIRC.  The make-kpkg method had no problem with 20%, but with
that method one can specify to build the image only, but the 'deb-pkg'
target apparently builds header and libc6-dev packages without one
asking for them and this may have something to do with lots of
additional space being allocated.

     Even after specifying env TMPDIR='/huge/harddrive/directory' the
dpkg-deb space seemed to hang/loop at the same place, though no message
regarding space was emitted, so that may have been a different problem.
In any event, more verbose messages seem warranted.  






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