> > I like the "min (256, MAX_OFILE_ALIGNMENT)" fix...
> 
> So do I.

Ok to apply then?  Tested via djgpp cross-compile and cross-host.

        * config/i386/i386.c (ix86_data_alignment): Don't specify an
        alignment bigger than the object file can handle.

Index: i386.c
===================================================================
--- i386.c      (revision 122271)
+++ i386.c      (working copy)
@@ -15417,7 +15417,7 @@
 int
 ix86_data_alignment (tree type, int align)
 {
-  int max_align = optimize_size ? BITS_PER_WORD : 256;
+  int max_align = optimize_size ? BITS_PER_WORD : MIN (256, 
MAX_OFILE_ALIGNMENT);
 
   if (AGGREGATE_TYPE_P (type)
       && TYPE_SIZE (type)

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