NZ Images were created on 9GB disk so any disk larger than that should be find.

The NZ images, except the thomson one are quite stable, and have been used without issue for a number of installs I am aware of.

I know jaidev had some problems with 300G (segate) disks, PM him and see what was up with that.

As for the IR codes, petestrash was enough to put the various NZ IR codes into the IR slice. If you install against the emulator, you should automatically get the codes you need.

This should give you a couple of things to try.