I have been following this thread with interest. I don't know if you are
familiar with the microcore linux, but maybe you should consider it for
the basis of the new player.
Microcore linux is a small linux (basis is only 8-12 MB), but it is
possible to add the packages that you need. It is so small that it can
be running entirely in RAM, and therefore no writing to the SD-card is
done. You only write to the SD-card when you tell it to do so

In addition, everytime it boots it is a "fresh" start, and the
extensions and changes are added to the core, so there is no risk of
corruption of the system or the card.

I have build a small squeezelite player with microcore linux for the
raspberry which is only 25 MB in total.
http://forums.slimdevices.com/showthread.php?97803-piCoPlayer-Squeezelite-on-Microcore-linux-An-embedded-OS-in-RAM-with-Squeezelite


There seems to be ports to other ARMS as well - maybe it is worth
considering?

Here is a link: http://forum.tinycorelinux.net/index.php/board,56.0.html
and another: http://forum.tinycorelinux.net/index.php/topic,14855.0.html

Steen


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