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

How old is your Arduino? Or did you load optiboot into a 328 yourself?
This was a well-known bug in the initially released version of optiboot, but it was fixed in the 1.0 timeframe (About two years ago.)
http://arduino.cc/forum/index.php/topic,28074.0.html