QUOTE (The Piney @ Apr 14 2008, 04:38 PM)
I found a couple posts on reducing the size of the image such as DigiWiz's post on removing un-needed Fonts from the output directory prior to building the ISO but I'm not sure what Fonts can be safely deleted. The Fonts directory under I386 is around 16MB so that seems like a good place to trim a bit of the size.
Sounds like you've made a good start - here's my 2¢, for what it's worth, which may only be that
My fonts folder, after cleaning out, is 1.83MB so you can save yourself about 14MB right there. Also, a little trick to save numerous MB in your fonts folder (can't remember how much - something like 2-4MB as I recall) is to use TTF from Windows 98. WinXP uses unicode fonts, which are MUCH larger, and serve no purpose in PE. So most of my TTF are ~60kb-80kb range, while equivalent XP unicode fonts are ~200kb-400kb range... so I substitute Win98 fonts for XP fonts via a tiny plugin. Everything works fine here. I'll gather up a list of minimal fonts you need and post later.
Another way to save many MB from UBCD4Win is to do a search for things like *.chm, *.hlp, *.txt, *.doc, *.rtf, *.pdf, *.wav, *.htm, *.html, *.log and on and on as you think of unnecessary things. Getting rid of chm and hlp files alone will save you roughly 14.5MB. Of course, you'll have to decide what you want to keep and what to get rid of. Some things I'm sure were necessary to remain in compliance with distribution of an application, but of course, since you are at home, you can do as you damned well please!
A few other options would be to use a few different plugins. The UBCD4Win Opera plugin is ~8.2MB, mine is 4.4MB. The UBCD4Win Firefox plugin is ~25.2MB, mine is 6.7MB. The UBCD4Win Filezilla plugin is 12.1MB, mine is 1.2MB (yes 1.2MB!)
By a quick very approximate count of my tips above, you can save at least 61MB - and that's just the beginning! I have a little script which also deletes unnecessary dll's, exe's etc. from system32 folder as well as lots of language files (.nls files).
So since it sounds like you're diving in to completely customize your build, make sure your mask fits snuggly, and you have plenty of air in your tanks
Once you put all that work into customizing your UBCD4Win, leave it the hell alone! As you can imagine, downloading the newest, latest, greatest version will destroy all the hard work you put into customizing your "personal version."
So here is some constructive critcism (though honestly, it seems sometimes any criticism here is frowned upon and folks get jumped on for it. Oops - I ended a sentence with a preposition - my bad

) Honestly though, no disrespect intended. Here's my idea for a perfect UBCD4Win world:
There would be the full, neophyte/newbie version, which is what... over 200MB now? Can't remember... this utilizes an installer, which, though I might disagree on it's implementation as it gyrates through decompressing files and innumerable hash checks... anyways - this would be geared toward to first-time user and/or inexperienced computer user, who doesn't know, or doesn't want to know anything about plugins - they just want something that works.
Then there the thousands of the rest of us, who like to tinker... there would be a separate "updates only" version, which, as you can imagine, would be tiny in comparison. It would be a rar or zip file, containing ONLY the changes from the last version, which, as you can imagine, would be plugin updates, and maybe other little tweaks here and there. Since this would be aimed solely at the experienced user, there'd be no "official" support - since the assumption is made, and would be explicitly advertised with the caveat: FOR THE EXPERIENCED USER ONLY. With an "updates only" package, an experienced user such as yourself, could pick and choose what, and how, you decide to implement these minor changes.
Well, there you have my small post on how to prune your UBCD4Win build