@Derek-Newbold As a very first step I may ask you to post a picture of the error that you see on screen when an image does not properly deploy “due to image size being set to 0”.
While I can’t be absolutely sure (there have been many changes and fixes since FOG 1.5.4) I am not aware of the image size playing any role when deploying an image to a host! It’s true that in FOG 1.5.4 the image size on client field is being updated and set to 0 if it fails deploying and that is something strange we fixed lately. It will only ever do this on captures now.
Nevertheless I don’t think the image size should influence the deployment process in any way. Please provide error messages.