I'm glad it worked out. I wouldn't have guessed that that feature worked that way. I forget which optimizations are in "-Os", but in general I wouldn't be surprised to see the code for some functions inline-d and/or broken up, such that they didn't appear as units any more. Some functions might indeed completely disappear, if the optimizer's analysis concluded they couldn't ever be called. Also, don't be too concerned about the raw size of the .ELF file -- the newer compiler may just be putting in more extra stuff (debug information, e.g.) than the old one. The msp430-elf-size output shows what's actually going into the device.
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