[Miscellaneous Android Development] kieranc:
I have 3216Kb free having removed:

@@ -16 +15,0 @@
-system/app/Bluetooth.apk 383924
@@ -35 +33,0 @@
-system/app/Email.apk 1219459
@@ -40 +37,0 @@
-system/app/LiveWallpapers.apk 3981522
@@ -48,2 +44,0 @@
-system/app/PicoTts.apk 16397
-system/app/Protips.apk 93369
@@ -52 +46,0 @@
-system/app/RomManager.apk 1848588
@@ -61,2 +54,0 @@
-system/app/ThemeChooser.apk 28028
-system/app/ThemeManager.apk 332246
@@ -66,3 +57,0 @@
-system/app/VisualizationWallpapers.apk 169883
-system/app/VoiceDialer.apk 110188
-system/app/VpnServices.apk 33826
@@ -428,32 +416,0 @@
-system/media/audio/ringtones/BeatPlucker.ogg 28433
-system/media/audio/ringtones/BentleyDubs.ogg 30759
-system/media/audio/ringtones/BirdLoop.ogg 41828
-system/media/audio/ringtones/CaribbeanIce.ogg 30615
-system/media/audio/ringtones/CrazyDream.ogg 206809
-system/media/audio/ringtones/CurveBall.ogg 30925
-system/media/audio/ringtones/DreamTheme.ogg 175423
-system/media/audio/ringtones/EtherShake.ogg 31563
-system/media/audio/ringtones/FriendlyGhost.ogg 46425
-system/media/audio/ringtones/GameOverGuitar.ogg 49978
-system/media/audio/ringtones/Growl.ogg 41094
-system/media/audio/ringtones/InsertCoin.ogg 15146
-system/media/audio/ringtones/LoopyLounge.ogg 38307
-system/media/audio/ringtones/LoveFlute.ogg 34627
-system/media/audio/ringtones/MidEvilJaunt.ogg 28124
-system/media/audio/ringtones/MildlyAlarming.ogg 34864
-system/media/audio/ringtones/NewPlayer.ogg 15563
-system/media/audio/ringtones/Noises1.ogg 36287
-system/media/audio/ringtones/Noises2.ogg 39025
-system/media/audio/ringtones/Noises3.ogg 26662
-system/media/audio/ringtones/OrganDub.ogg 32640
-system/media/audio/ringtones/Ring_Classic_02.ogg 59024
-system/media/audio/ringtones/Ring_Digital_02.ogg 21007
-system/media/audio/ringtones/Ring_Synth_02.ogg 52809
-system/media/audio/ringtones/Ring_Synth_04.ogg 43965
-system/media/audio/ringtones/RomancingTheTone.ogg 31641
-system/media/audio/ringtones/SitarVsSitar.ogg 28898
-system/media/audio/ringtones/SpringyJalopy.ogg 26144
-system/media/audio/ringtones/Terminated.ogg 36620
-system/media/audio/ringtones/TwirlAway.ogg 26298
-system/media/audio/ringtones/VeryAlarmed.ogg 28691
-system/media/audio/ringtones/World.ogg 31136
@@ -467 +423,0 @@
-system/media/bootanimation.zip 1756856
@@ -565 +520,0 @@
-system/xbin/irssi 2953820
@@ -576 +530,0 @@
-system/xbin/openvpn 359412
@@ -596 +549,0 @@
-system/xbin/tcpdump 621332
@@ -599 +551,0 @@
-system/xbin/vim 873780

With these removed, the zip will be small enough to flash and leave space for gapps.

I thought I'd removed some libs but apparently not, will try ditching the libbluetooth ones, see what happens. Should still be possible to lose some more:

ADWLauncher.apk, BooksPhone.apk, CarHomeGoogle.apk, FileManager.apk, GenieWidget.apk, LatinImeTutorial.apk, LiveWallpapersPicker.apk, - All tested OK to remove. 6.4MB free!

Mms.apk, Phone.apk, Stk.apk and TelephonyProvider.apk. Should be possible to clear another 4MB ish.

I'll have a play, see how low I can go :)

Final edit, having removed everything listed in this post:

Filesystem 1K-blocks Used Available Use% Mounted on

/dev/block/mtdblock2 155648 145392 10256 93% /system

10MB! :) Market seems to be FCing a bit after removing the lat few, not sure if it's related as i didn't test as extensively before removing... still works though.