Unfortunately, there are many things that may be wrong here, and there is not enough information in your message to track them. Instead of an answer, here is a debugging tip. Take a look at the _validateControllerClassName function.
protected function _validateControllerClassName($realModule, $controller) { $controllerFileName = $this->getControllerFileName($realModule, $controller); if (!$this->validateControllerFileName($controllerFileName)) { return false; } $controllerClassName = $this->getControllerClassName($realModule, $controller); if (!$controllerClassName) { return false; } // include controller file if needed if (!$this->_includeControllerClass($controllerFileName, $controllerClassName)) { return false; } return $controllerClassName; }
Each return false is a state in which Magento may decide not to use your controller class for the request. Try adding some logging or var_dump input to $controllerFileName , $controllerClassName , both inside and outside the if statements. This is usually enough to indicate a small error in the name of the path to the file or class (case, missing character, etc.) for your module.
If you do not see any information related to Custom_Checkout , it means that Magento cannot see your module, and you should start debugging this.
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