Ok, so I think I figured out the boardconfig.mk issue.
I searched [FINAL] 3/18/2011 CWM Recovery on Dell Streak 7 - xda-developers
and found that someone suggested using
BOARD_BOOTIMAGE_MAX_SIZE := $(call image-size-from-data-size,0x00280000)
BOARD_RECOVERYIMAGE_MAX_SIZE := $(call image-size-from-data-size,0x00500000)
BOARD_SYSTEMIMAGE_MAX_SIZE := $(call image-size-from-data-size,0x07500000)
BOARD_USERDATAIMAGE_MAX_SIZE := $(call image-size-from-data-size,0x04ac0000)
I then ran
make -j4 recoveryzip
And didn't get an error. So, hopefully it worked. It even gave an output that was in the correct update.zip format, so seems good. I'm not going to flash on my phone right now cause gotta prepare dinner, but will test tomorrow. For anyone wanting to test it. Use the method to get into our stock 3e recovery. VOL DOWN - F - A- then when android pops up hit softkeys. then select flash update.zip. Do this at your own risk. If you got work early tomorrow, don't do it, if you got some important use for your phone coming up, don't do it. Just wait a bit until I can test it.
md5sum for this update.zip is