Hi Eliot,
seeing these 2 lines in BuildSqueak45Image.st

                "('http://www.squeaksource.com/FreeTypePlus'    5    ('FreeType')) can't load this.  it is toxic to Squeak 4.5"
                ('http://www.squeaksource.com/FreetypePlugin'    8    ('Freetype-Plugin'))

that reminds me i have opened an alternate repository not toxic for Squeak 4.x :

MCHttpRepository
    location: 'http://ss3.gemstone.com/ss/FreeTypePlus'
    user: ''
    password: ''

cheers

Nicolas