Are you certain that you have icons showing next to items in the overflow menu? This is intentionally not allowed:
Displaying icon for menu items of Action Bar in Honeycomb android 3.0
It seems like there are several hacks to make something like this work. Maybe you're using one of them and it's what's causing your crash.
However if you want full control over this, it may be best to extend PopupWindow
and simply inflate whatever layout you'd like into it. You could then create a 'fake' overflow button in the action bar and configure the PopupWindow to display beneath it.