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Because files are compressed to varying degrees as the ROM image is created. Current rough estimates are that your dump folder (located in \temp after you run buildos) can be around 87-89MB and still fit. The only logical way you can squeeze 87MB into 64MB is via compression.
And yes, buildos gives you no indication of size so at this stage in the game you'll have to do the addition by yourself.
Considering the cost though (and the alternative), what we have is pretty damn amazing in my opinion.
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