Mikhail Dikov's post covers it all :) We've been struggling with half deployed SharePoint solutions a for an hour wondering why not all the files are added to our WSP file. 1424 KB sounds a lot like a 3,5" floppy... Anyway, the tip of the day is:
"Couple of days ago we added a big zip file to our SharePoint deployment and out of the sudden the solution started behaving strangely. After some trial and error Robin found out that every time we cross the 360KB limit we have a problem. Wait, 360KB this rings the bell, but it was such a long time ago. What was it? You guessed it right the default limit for file size of makecab.exe is 360KB the size of 5.25 inch diskette. Talk about legacy support... To disable all kinds of limitations I added these lines to my DDF files and everything worked fine again."
.Set CabinetFileCountThreshold=0
.Set FolderFileCountThreshold=0
.Set FolderSizeThreshold=0
.Set MaxCabinetSize=0
.Set MaxDiskFileCount=0
.Set MaxDiskSize=0
Lucy, thanks for Googling!
PS: did I already mentioned out free downloadable Tam Tam solution management tool of remote deployment?