Is it possible, and if so have you tried to remove files that you won't need? (e.g. any unused locales, screen modes, etc)?
Ow I have to do that or it wouldn't fit for sure. Almost all Locals and printers as well as a good chunk of fonts and a few other things. Removed duplicate mountlist and icons to copy/create and reposition them later. Created a custom install script. And crunched/packed just about everything left.
Ah okay, it's been a while since I used it (1990's)! I'll have to play around with it again at some point. So there must be a choice then between external library (explode) and internal decompressor (inside executable)... and if you have more than one crunched executable then the library would be more space efficient.
So anyway, you're trying to squeeze the OS3.1 disk set onto just one floppy? It certainly sounds ambitious. How small have you gotten it up to yet?
I only have HDToolbox Imploder crunched since I don't want it to be crunched on the HDD and I can use deploder for that and having the imploder lib in the exe doesn't add much to the filesize so more spacesaving that way. UnLZX is Shrinkler compressed and doesn't need any library. Rest is either in LZX archive or can't be crunched/packed due to the nature of the file (such as startup-seq, a readme file, L:fastfilesystem)
It fits right now but as said to puppypc I've had to remove some nonessential files, but I want that at a minimum so any space I can save goes towards making it more complete again.
Without commenting on the lawfulness of the chosen data... Which would be perfectly OK if the person using it has an actual ROM chip somewhere in their collection. (Will Amiga Inc ever sue Mac over that, I wonder? Seems fair, it was the other way around in the past). Anyway...
That is your problem, doing single fles rather than a single joined up one. When you use any data sector, any unused space is wasted on the last sector. That is why arranging the data into a single set, then compressing that set into a single file, is going to save you space.
The snags are two fold - first, you need a fast Amiga with lots of fast RAM to set it up - second, your compressor has to first uncompress the archive, the correctly chop it up into single files and copy them to the HDD. You have set no margin for error on doing that on a 1MB single floppy with a HDD attached. But, I admire your thoroughness in pursuing that goal - trying to get it universal.
Here's a simpler way - do it as 2 disks. One as the uncruncher. The next one, when booted, splits up the decompressed file, makes a new set of sub directories, and copies all the split files into the right places. That might just work, and give the end user a nice front end when setting the thing up. The snag is, the decrunching has to happen on one file, which has to be gradually read in, decompressed, and copied to the hard drive. Very demanding.
It does mean two boots from different floppies, but it gives both you and the end user some control over how their hard drives will be setup. That might not seem an issue. Well, it is if the end user is running a real 1.3 Amiga. Having a warning saying "this isn't going to work without a ROM change" would be very helpful to noobs with Amigas, for instance.
Even if you don't for the single file option (it is very challenging), a second floppy for excess data and setup might be required anyway. For files crunches that won't fit, and also for the setup. It would save one reboot, so might be a bit quicker for the end user.
About legal... as long as I have it for personal use and for friends and others who own the WB3.1 I see no legal problems. Sure it might eventually leak onto the internet but that won't be my doing.
I use LZX merge option and it compresses it nicely... there's actually only about 1.2KB to save from putting everything into one uncompressed archive before compressing it and I decided that the extra memory requirement and decompression time wasn't worth it. That said 7z would compress it way harder so I'm still hopeful it'll be the next space saving step.
Everything fits way too easy onto a HD floppy (very first incarnation of this project) or 2 floppys... I've created a second Extras disk just to make the installation complete again and that one also includes big hdd support, pfs, sfs, , 060 libs, pcmcia cf support, magicwb and a few other addons. But it's optional "extras"... I want the challenge of making it a standalone 1 disk option mainly cause one of the reasons for this project was to remove the need for swapping floppies and another reason was so you don't have a corrupt disk X of 6 preventing you from completing the installation.