pfSense

I expect we can shrink that down considerably to get under 100 MB. It has to be including a number of unnecessary things to get to be that big, and even 2.0 and prior have at least a few unnecessary binaries that should be removed.

I'm sure there is a way to shrink it. Currently the kernels take up more room than anything else (combined, essentially)

Here are the largest things in the Full Update amd64 image for 2.1 on 9.x:

$ tar tvzf pfSense-Full-Update-2.1-DEVELOPMENT-amd64-20120121-1456.tgz | sort +4 -rn | more
-rw-r--r--  0 root   wheel 11225044 Jan 21 08:58 ./kernels/kernel_wrap_Dev.gz
-rw-r--r--  0 root   wheel 11087189 Jan 21 08:58 ./kernels/kernel_Dev.gz
-rw-r--r--  0 root   wheel 10976697 Jan 21 08:58 ./kernels/kernel_SMP.gz
-rw-r--r--  0 root   wheel 10976695 Jan 21 08:58 ./kernels/kernel_uniprocessor.gz
-r-xr-xr-x  0 root     wheel 10152659 Jan 21 04:25 ./boot/kernel/kernel.gz
-rw-r--r--  0 root   wheel  8624207 Jan 21 08:58 ./kernels/kernel_wrap.gz
-r-xr-xr-x  0 root     wheel  6223104 Jan 21 08:57 ./usr/libexec/cc1
-r--r--r--  0 root     wheel  3794596 Jan 21 08:56 ./usr/lib/libc_pic.a
-r--r--r--  0 root     wheel  3288542 Jan 21 08:57 ./usr/lib/libcrypto.a
-r--r--r--  0 root     wheel  3248914 Jan 21 08:56 ./usr/lib/libc.a
-r-xr-xr-x  0 root     wheel  2964432 Jan 21 08:59 ./usr/local/bin/php
-r--r--r--  0 root     wheel  2866812 Jan 21 08:57 ./usr/lib32/libc_pic.a
-r--r--r--  0 root     wheel  2188798 Jan 21 08:57 ./usr/lib32/libcrypto.a
-r--r--r--  0 root     wheel  2180154 Jan 21 08:57 ./usr/lib32/libc.a
-r-xr-xr-x  0 root     wheel  1952543 Jan 21 08:59 ./usr/local/lib/php/20090626/mbstring.so
-r-xr-xr-x  0 root     wheel  1930032 Jan 21 08:58 ./boot/kernel/zfs.ko
-r-xr-xr-x  0 root     wheel  1849824 Jan 21 08:59 ./usr/local/sbin/dhcpd
-r--r--r--  0 root     wheel  1751200 Jan 21 08:57 ./usr/share/misc/magic.mgc
-r-xr-xr-x  0 root     wheel  1739616 Jan 21 08:59 ./usr/bin/dig
-r-xr-xr-x  0 root     wheel  1729088 Jan 21 08:59 ./usr/bin/nslookup
-r-xr-xr-x  0 root     wheel  1728784 Jan 21 08:59 ./usr/bin/host
-rwxr-xr-x  0 root     wheel  1717360 Jan 21 08:59 ./lib/libcrypto.so.6
-r-xr-xr-x  0 root     wheel  1698280 Jan 21 08:59 ./usr/bin/nsupdate
-rwxr-xr-x  0 root     wheel  1514872 Jan 21 08:59 ./usr/local/lib/libxml2.so.5
-r-xr-xr-x  0 root     wheel  1455184 Jan 21 08:59 ./usr/local/sbin/dhcrelay
-r--r--r--  0 root     wheel  1435640 Jan 21 08:57 ./usr/lib32/libcrypto.so.6
-r--r--r--  0 root     wheel  1343488 Jan 21 08:57 ./usr/share/misc/termcap.db
-rwxr-xr-x  1 root     wheel  1315160 Jan 21 08:59 ./lib/libc.so.7
-r-xr-xr-x  0 root     wheel  1284920 Jan 21 08:59 ./usr/local/bin/links
-r-xr-xr-x  0 root     wheel  1276200 Jan 21 08:57 ./usr/bin/ld
-r-xr-xr-x  0 root     wheel  1172096 Jan 21 08:57 ./usr/bin/as
-r--r--r--  1 root     wheel  1096236 Jan 21 08:57 ./usr/lib32/libc.so.7
-rwxr-xr-x  0 root     wheel  1077061 Jan 21 08:59 ./usr/local/lib/libiconv.so.3
-rwxr-xr-x  0 root     wheel  1039640 Jan 21 08:59 ./usr/lib/libstdc++.so.6
-r-xr-xr-x  0 root     wheel  1011008 Jan 21 08:57 ./usr/bin/objdump

(That is every object >1MB)

About half the size of the entire image is kernels.

Not sure why the UP kernel is in that list either, since we don't use it. There's ~11MB right there...