./build.sh distribution consistently breaks on my 2.1_RC4 machine: 

all ===> i386/floppies/bootfloppy-tiny
Copying /cvs/obj/destdir.i386/usr/mdec/boot to boot
Creating USTAR.volsize.4540
Copying /cvs/obj/distrib/i386/floppies/instkernel/netbsd-INSTALL_TINY.gz to netbsd
Creating boot-tiny1.fs from: boot USTAR.volsize.4540 netbsd
Running instboot: /cvs/obj/tooldir.NetBSD-2.1_RC4-i386/bin/nbinstallboot -mi386 floppy.20212.tar /cvs/obj/destdir.i386/usr/mdec/bootxx_ustarfs
buildfloppies.sh: Image is 16384 bytes (16 KB) too big to fit on 1 disk

*** Failed target:  boot-tiny1.fs
*** Failed command: PAX=/cvs/obj/tooldir.NetBSD-2.1_RC4-i386/bin/nbpax sh /cvs/src/distrib/common/buildfloppies.sh -i "/cvs/obj/tooldir.NetBSD-2.1_RC4-i386/bin/nbinstallboot -mi386 @IMAGE@ /cvs/obj/destdir.i386/usr/mdec/bootxx_ustarfs" -p -m 1 -s .fs boot-tiny 2400 boot USTAR.volsize.4540 netbsd
*** Error code 1

This is after successfull build of all sets and kernels...  

GH