Additional musings. You said insmod crashes. Insmod loads modules. The modules are built in another compile operation from building the kernel. Kernel and modules have to be built from the same headers and so forth. Are all the modules built during the kernel build, or are they "existing"?
The other idea, and something I know little about, is svn externals, which (if used) can affect what is checked out to your project. Look and see if this is any different when exporting.