pYro_65:
Of course we can only speculate without your code to test. Some of your claims seem a bit far fetched and there is probably something else causing a problem.
http://vftp.net/n0zyc/CleverFox/CleverFox_Project.zip
It compiles right now to about 30k. Open the Config module and comment out "#define debugging_serial" and compile again. Compile size here jumps to 35k. Which is really annoying because it won't fit on an Uno then. And all those Serial.print are killing its limited sram unless I turn off debugging.
99% of debugging_serial's effect is to remove code from the build. There are a handful of lines of code in one place that are substituted, but nothing that should bump compile size (I tried moving them out of the #else and it didn't really matter) Just look for #else if you want to see them.