If I recompress an untouched V3.6 I get a larger iso that won't fit on a CD also. Since I am removing almost everything, I didn't worry about it. There is an option to the compresser to try to get the most compression but instead of taking 35 minutes when not using the option it took about 14 hours and it only saved a couple percent of space. It was not worth it for my configuration since I am compressing about 300 megs down to a 124 meg iso and can easily fit on a mini CD. All my remasters boot and run from my test partition including recompressing the whole distribution. If your remaster won't run maybe there is something you need to change to your scripts when remastering V3.6