I've worked on a couple of projects that only had a few bits of free ROM left. Not really all that surprising, you stop optimizing for space once it fits.

One of the projects was heavily squeezed to make it fit, the other didn't need much squeezing, but you couldn't tell the difference by looking at the free space.

If you like that, you have to read this (in 13 parts): http://all-things-andy-gavin.com/2011/02/02/making-crash-ban...