Thanks for all the advice. The key things I've gotten so far is:
1. epubs are already compressed, so zipping won't save me anything.
2. Sigil recommended to edit epubs to take out non-text.
3. 1 GB SD card should be plenty of space for even a big collection.
If I have a bunch of nice text-only epubs in my Calibre library, but have a cover file for each book (it looks like Calibre stores these as jpgs, outside of the ebook file, no matter what formats you have), and then make some changes to my metadata that I want to get into the epub files, my understanding is that I need to reconvert - ie epub to epub. When I do that reconvert, what options do I set to make sure it doesn't put that cover file into the epub file?
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