I don't know which version you're using (of gcc), but one of them notes that
when configuring as a cross-compiler, to specify --use-gas or something like
that. (I also realize that it says that that doesn't matter for certain
configs, but I don't have INSTALL around right now to read it). If the
loader or 'file' is barking about a bad magic number, it sounds like
either the wrong assembler or the wrong loader is being envoked. (Or
both). I also think (but I'm probably wrong) that the as86 should be in
the same directory as cc1, cpp, ld, libgcc.a, as 'as', and, failing to
find it as that, gcc will envoke 'as' w/o the gcc directory prefix,
finding the system assembler, which will then assemble the .s file to a
sysV image. If gnu's ld is then run, it will complain about 'bad magic
number'.
        Of course, I could be mistaken...

-- 
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Steve Rich
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