weird sketch size issues with Optiboot in Arduino 0022/0023 and Atmega328

i narrowed down the range of sketch sizes

Ah. I was wondering what you had searched for that hadn't turned up anything useful. AFAIK, few of the early reports of this problem went to the effort to determine the exact sketch size that caused problems. If you had googled "Uno sketch size hang", you would have had better luck...