I don't flash very often and use a similar management approach: a not-overpacked rom, cabs on the storage card -> about a dozen apps installed to the extended rom. These cab-installed apps are either old (Ewallet from PPC2002, Pocket Streets 2005), updated often (Phoneweaver, Google Maps), don't have an OEM in the kitchen (MemMaid 2.0, Twinky's threader), or just for trying out (Google Navigator). These might be a pain if I flashed more often - but since it only takes 5 minutes to install all of them it doesn't seem worth the effort to develop OEMs etc. FWIW.
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XV6700 w/ Custom Apache WM6 Kitchen CE OS 5.2.1908 (Build 18508.0.7.0) - from Helmi_c and the guys at PPCGeeks.com
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