@dlanor - The FAT32 partition and its contents survive. I think 256MB is minimum to hold the kernel/initrd and two .bz2 distro files. FAT32 is tested now, and is the way to go. Unfortunately I am still trying to get the "parted" command to compile. It has more than the usual errors, and is requiring many code mods... I still think it is possible to compile, so I will continue, but it may not be done for an evening or two due to the amount of troubleshooting involved. After it works I will consider examining user entry of sizes, but for now fixed is simple and is my goal.
PS2 v9 NTSC, PS2 v12 NTSC, PS2 v15 VESA