>Our current app's EXE is over 4 MB and still growing, it may reach 5 before all is said and done. We do netsetups, so that aspect is not a problem. But are there any other potential problems with this size, related to RAM? All users will be Win95 with data on NTServer...

It could slow things down abit as a lot more virtual (disk) RAM is used, especially if there a large number of objects in use at any one time. Other than that, if the RAM meets the minimum (yeah they say 8MB, think 12MB) there should be no problems.