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[TJ <ubuntu@xxxxxxxxxxx>]

Using debug information from icedtea the problem appears to stem from
"Error: create process":

  result = manager->CreateInstanceByContractID (NS_PROCESS_CONTRACTID,
                                                nsnull,
                                                NS_GET_IID (nsIProcess),
                                                getter_AddRefs (applet_viewer_process));
  PLUGIN_CHECK_RETURN ("create process", result);

which is called during initialisation:

ICEDTEAPLUGIN_DEBUG=1 firefox-3.5

...

Initializing JVM...
ICEDTEA PLUGIN: get component manager
ICEDTEA PLUGIN: liveconnect
ICEDTEA PLUGIN: thread manager
ICEDTEA PLUGIN: Instance::StartAppletviewer
ICEDTEA PLUGIN: get component manager
ICEDTEA PLUGIN: create local file
ICEDTEA PLUGIN: init with path
../IcedTeaPlugin.cc:3858: Error: create process
ICEDTEA PLUGIN: Instance::StartAppletviewer return
../IcedTeaPlugin.cc:1666: Error: started appletviewer
ICEDTEA PLUGIN: Factory::Initialize return

-- 
Jaunty icedtea6-plugin doesn’t work in Firefox 3.5
https://bugs.launchpad.net/bugs/359407
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which is subscribed to openjdk-6 in ubuntu.

Status in “firefox-3.5” package in Ubuntu: Confirmed
Status in “openjdk-6” package in Ubuntu: Invalid

Bug description:
On Jaunty amd64 with icedtea6-plugin 6b14-1.4.1-0ubuntu6, Java applets work in Firefox 3.0, but not in Firefox 3.5.  The following messages show up on the console:

$ firefox-3.5
../IcedTeaPlugin.cc:3852: Error: create process
../IcedTeaPlugin.cc:1662: Error: started appletviewer

(firefox-3.5:13746): GLib-CRITICAL **: g_io_channel_write_chars: assertion `channel != NULL' failed
../IcedTeaPlugin.cc:4061: Error: Failed to write bytes to output channel

(firefox-3.5:13746): GLib-CRITICAL **: g_io_channel_flush: assertion `channel != NULL' failed
../IcedTeaPlugin.cc:4075: Error: Failed to flush bytes to output channel

(firefox-3.5:13746): GLib-CRITICAL **: g_io_channel_write_chars: assertion `channel != NULL' failed
../IcedTeaPlugin.cc:4061: Error: Failed to write bytes to output channel

(firefox-3.5:13746): GLib-CRITICAL **: g_io_channel_flush: assertion `channel != NULL' failed
../IcedTeaPlugin.cc:4075: Error: Failed to flush bytes to output channel