There could be 3 points where you are having trouble 1. you haven't selected the proper config for yer sys. 2. selected your boot fs as a module 3. not used the latest modutils avlbl. at ftp://ftp.kernel.org/pub/linux/kernel/people/rusty/modules/module-init-tools-0.9.12.tar.bz2
There is one very imp. point i happened to note while working with 2.5.x kernels. It picks up the configuration of your current kernel if its lying around in your /boot or in /usr/src/xyz . This creates problems due to introduction of unwanted extraneous symbols and values.
So the best way is to touch .config before make xconfig or menuconfig.
also please read the readme in the modutils bzball closely else you'll end up messing up ur distro.
If you are uncomfortable with the modutils the best way is ofcourse compile nothing as a module. Build-in all possible options and check if it works.
hope that helps,
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