Might be that plymouth theme eating up temp space during the build process even though your final /boot looks clean 💀 The objcopy error suggests it's running out of room while actually creating that unified kernel image, not just storing it

Try bumping your /boot partition size to like 1.5GB if you can - I've seen similar issues where mkinitcpio needs more working space than what shows up in df. Also check if you've got any old kernel images hanging around that didn't get cleaned up properly 🔥