>That sounds odd. On my machine the full v4.0 framework (including temporary files that get added during use) is less than 400mb. But that includes versions for all platforms, WPF libaries etc. - you should be able to supply *way* less than that:
>http://www.hanselman.com/smallestdotnet/

Setup.exe is 418 KB and Setup.msi is 913 KB. I have a pre requisite for .NET Framework 4.0. That generates this pre requisite to be installed when Setup.exe runs, if not already there. When that was the case, it complains saying it required 2110 MB. Basically, we had to clear 2 GB for this installation to install.

>I believe Client Profile excludes most ASP.NET stuff. Although you get 'hundreds' of errors they *might* boil down to the use of just one excluded DLL or just a small bit of functionality that could be achieved differently.....

I found out that if I change my Framework.dll to target at the Client Profile that about 8 classes out of 10 cannot run. Things such as System.Web cannot be used with the Client Profile and so. Basically, how can someone build an EXE with the Client Profile if we are not even allowed to use the System.Web namespace. So, I had to switch all those settings back to the full .NET Framework 4.0. But, now, we have to add a requirement that 2 GB is required as free space on the drive. So, many customers will not like that.