Thanks guys, I will stick with TC for now using the "frugal" method which is how it installs TC on HDDs by default. curaga, I've found that extracting the extensions directly into the initrd results in faster boot times than loading extensions onboot (but as you said, this depends on the BIOS, CPU, etc.). I'm using mostly older hardware so doing all the extracting of the extensions beforehand saves time on boot, though it uses more memory. maro, ~10 second boot is very nice and more than acceptable for me, thank you for testing both methods.
I stuck with TC because of the support / regular updates, and more importantly, the modularity. It beats having to create your own embedded distro with buildroot, which is a pain dealing with makefiles and adding packages. I will see what I can do to totally optimize the boot process of TC. What I resorted to doing recently is leaving core.gz untouched, but chainloading this along with a customize.gz (which contains extracted extensions + other conf files) with extlinux so that upgrading is a breeze. This is essentially the same thing as remastering core.gz, but I just chainload another gzipped file that plops all my files over the core.gz initrd. I believe loading them onboot would result in less memory being used, but a slower bootup time, as shown in ixbrian's results here:
http://forum.tinycorelinux.net/index.php/topic,7002.msg36936.html.I will also try suggestions posted in this thread:
http://forum.tinycorelinux.net/index.php?topic=11235.0. < 10 seconds boot up is great, but < 5 seconds would be perfect. Hopefully these links help others looking to use this for an embedded platform as well, where speed is essential.