I was able to get the full compile to work when we used "configure -qt-zlib", but we could not get it to work when we used "configure -system-zlib".
We have the most current zlib files in our mingw folder (libz-1.2.3-1-mingw32-dev.tar.gz), but mingw32-make seemed to get confused as to which zlib files to use.
The original error message that was sent to you was produced when using "configure" by its self without any configure switches, but the same error occurred when using "configure -system-zlib". We have never had a problem with this in the past and that is why we found it odd.
I have the following in my Windows XP path: "C:\MinGW\bin;C:\MinGW\libexec\gcc\mingw32\4.4.0;C:\Qt\4.6.0\bin;"
I also have a user variable QTDIR that is set to C:\Qt\4.6.0\bin
I have a system variable that is called QMAKESPEC that is set to win32-g++