A standard large file problem and a standard solution: append-lfs-flags. This probably affects just x86 for obvious reasons. Minor request: if this gets fixed, could also DEFINES="-DSTRICT_ALIGNMENT_REQUIRED" be passed to emake ? This removes the warnings that __attribute__ ((packed)) with -O2 and above (as strict aliasing disables packing).
ive enabled lfs: http://sources.gentoo.org/app-arch/unrar/unrar-4.0.6.ebuild?r1=1.2&r2=1.3 i dont know what you mean wrt to alignment. i see no warnings on my system, nor does "strict aliasing disables packing" make any sense. packing doesnt make addresses of variables that were once unique now be shared.
OK, it was either older version of unrar (<3.9.7) or older version of gcc (<4.3.0) - I don't get that warning anymore either, I just didn't retest it.