I would look into kernel framebuffer issues, in addition the atv efi
firmware does not contain any traditional pc bios so any bios calls
the kernel makes will fail. This includes vbios. While there does
exist an nvidia vbios, it has not been setup. Only when X11 launches
with, does the nvidia X11 driver search, find and setup vbios.
The existing boot kernel used to construct the mach_kernel is
carefully configured to support the efi handoff that the code in
atv-bootloader does. Step outside this configuration and your kernel
will not boot or might boot and panic later but you will have no
indication. Also, any code changes that have occurred to boot
structures that are expected in atv-bootloader.
FYI, it took about three hard months to figure out the boot and
handoff to the kernel. I seriously doubt that just picking the
i386_defconfig and setting the processor is enough. You must match
how the existing boot kernel is configured and also take account any
code changes to the boot sequence.
The code in atv-bootloader is well commented, if none of that code
makes sense, then you need to spend some time learning how the linux
kernel boots before you can achieve your goal.