Very interesting question:

[Parker, Ron]

> -----Original Message-----
> From: Jason Clinton [mailto:jasonclinton at kcpipeband.org]

...

> * What is the best way to get 128mb of the best of the Linux
>    console in to that space?

...

I've never tried it myself, but you might look at the Linux Bootable
Business Card project.  Their ISO images are designed to be burned onto the
business card CD blanks and one of their nightly build ISO images appears to
only be ~49MiB, http://www.lnx-bbc.org/.  That should leave you plenty of
space to add your own interesting stuff but give you quite a bit more than
TomsRtBt.