After a little testing/scripting/playing with PHP 5.3 PHAR archives, I discovered some problems.
glob
PHAR doesn't work with glob. Neither as wrapper (http://www.php.net/manual/en/phar.using.stream.php#104320) nor as a function call.
In my test project I had to iterate over the files in the PHAR and filter the result by a glob-equivalent regular expression.
imagettfbbox
I have no idea why, but imagettfbbox also doesn't understand the PHAR stream wrapper.
The easiest solution here, was to extract the file via copy(). (PHAR::extractTo return with an exception without a stacktrace nor a line number.)
Are there other surprises, which I should expect? Are there other known issues? And are they documented anywhere?