IMHO [b:88e85f1b64]makeint()[/b:88e85f1b64] is not the evil part. It is a Mega1284P and a big program, right? - Sounds like a page boundary problem (RAMPZ) when reading the constant part of the [b:88e85f1b64]print[/b:88e85f1b64] statement in combination with soft UART. Maybe you send the program to support so Mark can investigate the position of the [b:88e85f1b64]print[/b:88e85f1b64] statement and the constant strings in memory.
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