I'm having similar problems trying to get the toolchain to build. I'm running Ubuntu 11.10 x64. I grabbed the latest revision with SVN and ran the download.sh script, followed by the unpack.sh script. Before running make, I changed the prefixes to this:
Code:
sh_prefix := $(HOME)/Dreamcast/dc/toolchain/$(sh_target)
arm_prefix := $(HOME)/Dreamcast/dc/toolchain/$(arm_target)
I ensured that I had build-essential, binutils, make, gcc, GMP, MPFR, MPC, etc. installed before running make. After a few minutes, it came back with an error.
Here's the log for the the newlib portion:
http://pastebin.com/hxVnUgYz. This is the error that killed the whole thing at the end:
Code:
checking for suffix of object files... configure: error: in `/home/wes/kos/kos/utils/dc-chain/build-newlib-sh-elf-1.19.0/sh-elf/newlib/libc/machine/sh':
configure: error: cannot compute suffix of object files: cannot compile
See `config.log' for more details.
configure: error: ../../../../../../newlib-1.19.0/newlib/libc/machine/sh/configure failed for sh
configure: error: ../../../../../newlib-1.19.0/newlib/libc/machine/configure failed for machine
configure: error: ../../../../newlib-1.19.0/newlib/libc/configure failed for libc
I would really appreciate it if someone could give me a hand with this

Here's the other logs if those need to be looked at:
http://pastebin.com/XRcHaNuK &
http://pastebin.com/4nTkcR9z