You could try Zipslack since that's fairly complete and is still small. The biggest problem you are likely to face is that, as far as I am aware, there are no BIOS manufacturers that support booting from USB devices, so you'd still need to either have a boot floppy, or use loadlin.
I think this has been discussed before now on these forums, but I'm not sure... have a peek.
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Oops... where are my manners? Welcome to LQ.
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