I can't build lib.pdf on MacOSX anymore. I tried both a4 and letter.
The pdflatex call fails with

Error: pdflatex: buffer overflow [125000 bytes]

The whole lib.how is attached (if I don't forget to check the 
checkmark:-).

pdflatex -version prints

pdfTeX (Web2C 7.3.3.1) 3.14159-0.14h-released-20010417

which seems to be newer than what the README lists as the minimal 
requirement.

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TeX systems tend to be a little weird about how memory is
allocated.
Most current distributions use a semi-static allocation
mechanism: Some large buffers are allocated once, and
everything happens within those.  The sizes are usually
configurable using a config file.

On my RedHat Linux box, which uses the "teTeX" TeX system,
there's a config file:

    /usr/share/texmf/web2c/texmf.cnf

This contains the following settings for pdfLaTeX:

TEXINPUTS.pdflatex = .;$TEXMF/{pdftex,tex}/{latex,generic,}//
main_memory.pdflatex = 1500000
hash_extra.pdflatex = 25000
pool_size.pdflatex = 750000
string_vacancies.pdflatex = 45000
max_strings.pdflatex = 55000
pool_free.pdflatex = 47500
nest_size.pdflatex = 500
param_size.pdflatex = 3000
save_size.pdflatex = 5000
stack_size.pdflatex = 3000

If you can locate the corresponding config file for your
system, please check the sizes configured and let me know
what differs. I may need to add some documentation about
this, mentioning that the Library Reference may take more
resources than are typically allocated.

Thanks!

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My texmf.cnf looks completely different. There doesn't seem to be a .pdflatex section, only the one TEXINPUTS line mentions pdflatex.

I've attached the file (name set to fink-texmf.cnf), maybe you understand it.

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Where a setting isn't specified but there is a "base"
variable (for example, main_memory is set, but not
main_memory.pdflatex), you can add the .pdflatex version if
the number is higher in the settings I included.  The
".pdflatex" suffix means that that setting applies to
pdflatex only; if such a suffixed version isn't set, the
bare "base" variable is used.

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That seems to work. I added the configuration lines to the end of /sw/share/
texmf/web2c/texmf.cnf and everything proceeds smoothly.

Could you add a note to the documentation readme file? The "/sw" location 
is specific to people who have installed the whole TeX circus with fink, but I 
assume that will be the common case for MacOS users.

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Added note about dealing with this memory consumption
setting in Doc/README revision 1.54.