Even though the problem has been resolved, perhaps someone is interested in this. A few months ago I needed to fine-tune a smal kernel. Over 2 days time I did over 120 kernel compiles, each time adding just one feature and then noting the size change. This was done with kernel 2.4.29 so the figures probably don't relate exactly, but it should give you an idea of the relative size of stuff anyway.
You can see my notes at:
http://distro.ibiblio.org/pub/linux/...ture-sizes.txt
Keep in mind that you onlyneed to hard-compile the features that you need to access your root file system and the device that it's on and certain features that can't be built as modules at all(if you need them).
Boot loaders DO care about the size of the kernel. ISOLINUX is the most forgiving and will let you boot kernels up to 48MB!
Zimage kernels are only possible below +-650K. Any bigger and you get: 'kernel too big for standalone bootup' -just means you have to use a bootloader, which is nearly universal anyway.
In case you want to manually install your kernel, after compiling the bzImage is located in:
arch/i386/boot (relative to the toplevel kernel source).