I've received several messages recently asking if this project was dead or not. Here's the current status: my personal firewall has been up for 483 days which should give you an idea of when I last touched it. The last FreeBSD release that thewall built on successfully was 4.5. The ISC dhcp client was updated prior to the 4.6 release and it has not built cleanly as part of a "crunch" since. I removed the dhcp client to find out what other problems would pop up and eventually got thewall to build on 4.8R. Unfortunately even without the (huge) dhcp client it no longer fits on a single floppy. This is not a shock as thewall only fit with about 30k to spare on the 4.5 release. So... since the 4.5 version fits my needs I’m declaring the project finished. Thanks to everyone who helped.
If you are searching for a FreeBSD based firewall that is being maintained I suggest you have a look at http://m0n0.ch/wall/ . m0nowall boots from a CD-ROM so it is not constrained by the limits of a floppy. A version for the soekris boards is also available.