Hmm. I just had a thought. Is there any reason that we can't partition the SD card into 3?
partition 1: fat32 - 16 megs for the zImage. Hell, it could be smaller if needed.. Or could it be on the ext3 partition?
partition 2: ext3 - 256 megs for the rootfs + room to grow (if needed)
partition 3: fat32 - remainder of the SD card. mounted in Linux as /apps, fat32 so that windows can read it.
I'm not sure, but would that affect the running of apps if they're stored on a fat32 volume?
Because if it won't affect that, I'll sit down and create a 4g image tonight that does just that.
At that point, it'd just need a menu system that auto-reads the /apps dir. Maybe it just looks for files named XXXX.app, so it knows what are apps and what's not? The apps like snes9x would need to have a file picker added, though.