Thought I'd follow up and let everyone know that I am now able to recreate
the stock kernel image.  The bottom line:  I wasn't able to reproduce the
compile errors after I posted to the list (of course).  Probable
differences: I may not have been running "make mrproper" each time, and I
started using "make oldconfig" instead of xconfig/menuconfig.

Here's the whole process, not much different than the HOWTO on kernel 
compiling.

1) cd /usr/src/linux/2.4.20-8
2) edit Makefile, pick a good name your kernel with the EXTRAVERSION var.
3) make mrproper && make clean  # start fresh
4) cp configs/kernel-2.4.20-athlon.config .config  # (I have an athlon)
5) make oldconfig  # create various setup files in the tree
6) make dep && make clean && make bzImage
7) make modules && make modules_install && make install
8) cp .config /boot/config-2.4.20-8_YOUR_KERNEL_NAME

The "make install" step might be controversial because I don't see it
mentioned much.  It might be new (?).  It worked for me, however, neatly
updating /boot with the image and system map, as well as updating
/etc/lilo.conf

The "make clean" after "make dep" may be unnecessary but it doesn't seem 
to hurt.

Note that the resulting image fails to binary-compare to the stock image,
so strictly speaking I haven't recreated the image.  Not sure of reasons
for the differences - possibilities include a different environment at
RedHat, timestamps within the image, and kernel name within the image.  
But it seems to boot the same.

More interesting to me was how to use the .src.rpm from RedHat's updates.  
You create the kernel-source.i386.rpm and kernel.i386.rpm with this
command:

rpmbuild --rebuild kernel-2.4.20-18.9.src.rpm

This will create, and install:

kernel-source-2.4.20-18.9.i386.rpm
 and
kernel-2.4.20-18.9.i386.rpm

in /usr/src/redhat/RPMS/i386

Then, you'll have the updated source in /usr/src/linux-2.4.20-18.9

Fairly automatic and nicely done...

Thanks to Peter Skensved and Steven Orr for the off-line dialogs, and to 
others for the list replies.

-- 
Greg Bell










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