How do I manage the size of a virtual appliance such that I can minimize the size of the distribution, but expand the size of the VMDK when it is installed at a customer location?
See the answer above regarding packaging options. Actually “growing” a virtual disk (increasing the total block count of the device) requires Guest OS level interaction to adjust file system parameters in most instances. Some software developers have elected to provide instructions on adding a virtual disk at installation / provisioning time, typically for arbitrarily large “data” disks which the virtual appliance can prepare for use automatically.
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