Much depends on what youre going to use it for:
Swap: 512M, at most... if the box has a good amount of memory you can scale that back to 256M
Boot: 125M, you can go lower but when you update a Linux kernel many distros leave the old one there as a fall back if the update breaks something.
Usr: if this box is just for home use I would not bother with a usr partition, just put the rest in '/'..
When I copy the boot.lnx using dd if=/dev/hdb2 of=/mnt/boot.lnx bs=512 count=1, the boot.lnx file contains a bunch of gibberish with something to the effect of "disk not bootable" embedded inside.
Any ideas? This is driving me crazy. I've been trying to get Linux to boot for like 2 weeks or more.