I found that the MINIROOTSIZE=3600 is not enough. 3960 is the minimum and I used 4200. I've now found that 1440k is not big enough for boot.fs does that matter? or do we trim stuff from INSTALL until it fits? 1440k is the size of a floppy...so this is definately a big problem. we need to switch to ustarfs, or something, i guess...