We have just under 500 switches in production (various models but for this discussion we'll stick with 3750's). All are currently running tar IOS (web based). We want to upgrade the IOS from c3750-ipbasek9-tar.122-55.SE1.tar to.122-55.SE5 but some of our switches do not have enough flash to upgrade successfully. We use CiscoWorks to distribute our software upgrades. I know you can lower the flash requirements on the IOS in CiscoWorks, which I have done (changed from 16Mb down to 12Mb) and the upgrade still fails.
1) How far can I lower the flash installation requirements in Ciscoworks and what are the ramifications?
2) If we decide to change from the tar IOS version to the bin IOS version because we don't even use the web based features anyway, is there an easy way to do this? (CiscoWorks will not upgrade an image from tar to bin)