After making, installing, and testing 58 different nLite setups I've managed to get my image down to 136MB, which makes for a 324MB install with out anything but XP SP2. This includes all the componenets needed to run FrodoPlayer and it's supporting software.
In the end I removing all but Defrag, USB Sound Support (With this I dont need to install the bloated Creative driver.), Speech Support, Windows Media Player, Windows Media Player 6.4, MDAC, COM+, Distributed Link Tracking Client, and Distributed Transaction Coordinator.
I should probably see if I can remove the tracking client with a FAT32 install.
FAT32 is better for Flash cards, right?
I cant figure out how you guys are getting the total install under 1GB with the hibernate and destinator (I'm assuming only 1 map?). I've installed all the apps on a second drive. So on my main partition I only have XP SP2, Speech SDK (with all docs and samples removed), WMP10, Drivers, and the DirectShow filters required for Frodo (Quicktime and Real alternative are installed on the second drive). Right now i'm sitting on 1.12GB. Any suggestions?