The kernel itself must be a certain size because it needs to be loaded in a fixed memory size. This is one reason why modules can be very handy. If you enable modules, you will need to make them:
make modules
and install them:
make modules_install
Then using the modprobe utility you can load selected modules on bootup. This way the kernel will be smaller and will compile with no error.
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LILO can't find a kernel on a big drive
On some big hard drives, LILO can have problems loading your kernel. The problem is because the hard drive has more then 1024 cylinders.
The trick is to make sure your kernel is in the first 1024 cylinders so LILO can find it. The way to do this is to make a small /boot partition at the begining of the drive, and make sure the kernel is in the /boot directory.
You can set the partitions in fdisk, and select the right path for the kernel in /etc/lilo.conf so LILO knows where it is. When you compile your kernel, simply move the new kernel in that directory so LILO can load it.
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Multiple kernels choices
When you compile a new kernel, you will often change your configuration. This means you may forget to include an important driver, like the IDE driver, or otherwise make your system unbootable. The solution is to always keep your old kernel.
When you compile your kernel, the compilation procedure will often copy your old kernel into vmlinuz.old.
If it does not, you can do it manually. What you should do is add an entry to /etc/lilo.conf allowing you to boot your old kernel. You should view the lilo man page for the complete syntax. You could also add entries for different kernels, for example if you want to have an older stable version of the kernel and the newest development version on your system.
Note that some distributions name their kernel with the version they represent. For example, your current kernel may be /boot/vmlinuz-2.0.36-0.7
