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Adding -freorder-blocks to the compile options fixes a random crash problem I was having with a large project. It does not increase the code size all that much when enabled... on average 200 to 400 bytes of flash are consumed on a large project.
It is obvious that -Os by its self can in some cases generate bad code, and this is an acceptable tradeoff. i.e. works, instead of banging your head on the desk wasting time trying to find out why your code is broken, when it isn't.