I am afraid I do not understand now. I was thinking the only reason to chop the number up (factor it) was because at one point the value was larger than 32 bits, then once that was dealt with 16 bit had it covered.

Is the math working correctly now for your formula?

What am I missing here.

As far as the code size goes with PBPL, every value is a LONG, even 1. So that is where the extra code space comes from.

I did not mention in the previous mail that I don't trust in PBPL, as it seems to me that it can not correctly show how much space your code will take when you are as close to the limit as 3k or so.
The code space used as far as I know is calculated correctly in PBP or PBPL. What is making you think other wise?