Since I incorrectly guessed that WIX was causing problems with my patch build, 
and in case this is of any use to anyone else trying to build patches, I 
thought I would pass along a some information that I've learned.

For various reasons, our product setups are built using a number of merge 
modules that package our own build products. This, along with my not thinking 
about the consequences, resulted in my previous attempts violating at least 3 
of the rules that MS documents governing proper patch builds (ref 
http://msdn.microsoft.com/en-us/library/aa368060(VS.85).aspx). Specifically, 
the file sequences were changing because files were added in the middle of the 
sequence, and files were deleted. Also the order the merge modules were 
referenced was inadvertently changed, which ends up changing the file sequence. 
All of these errors resulting in MSIMSP incorrectly believing that almost all 
the files had been ADDED as a part of the patch.

The bottom line is that if you are building your own merge modules, you'll need 
to keep the following tips in mind:
1) For updates of existing modules, you need to update the ORIGINAL merge 
module that contained that module. Meaning that you cannot make a 1.0.1 merge 
module with the updated file, you need to REBUILD your 1.0.0 merge module with 
it instead.
2) In order to ADD any files to your product release, you either need to add 
them to the main product setup, or you need to make a new/additional 1.0.1 
merge module containing only the new/additional files.

Following the rules (which is tedious, I must admit), has brought my patch size 
from 294MB (nearly the size of the full installer) down to 72MB (not small, but 
a LOT better).

FYI,
John Schmitz
Media Cybernetics


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