Yes..it is ok to have an older version of boot image when using a newer version of IOS. I don't see an option to upgrade the size of the bootflash on the NPE. You can put the boot image in the regular flash.
Starting 12.2(18)SXF code, a compact flash in place of bootflash is being supported. So, sup-bootdisk is a replacement for sup-bootflash.http://www.cisco.com/en/US/docs/switches/lan/catalyst6500/ios/12.2SXF/native/configuration/guide/sup720.html#wp1...
- Are you performing any kind of routing on the Switch or is it purely layer 2?- You cannot configure an IP address as default gateway if it is not in the same subnet as the PCs IP address. The PC uses the default gateway to send traffic to subnet...
