OK I have my Win7 aio that I made.

I am adding a @31 meg addon to it. After adding my wim is 1gig bigger.

WHAT?!?!?

Can you explian to me all of the extra size?

What are you using to make it WAIK?

I made the a-i-o with WAIK. And it worked as expected. 3.65 gigs for the final all-in-one size.

However, after adding a 39meg addon to them using win7 toolkit it grows to @4.6 gigs...

Make sure W7T Temp file are deleted, usually C:\W7T

Ok I will try that.