With regard to the Cava Packager section of your post:

You can package any number of executables to use the same modules and libraries. This is part of the build process covered extensively in the help. You are right to say that overwriting one set of files with another will cause the first set to malfunction.

The 'stunning' number of files is probably due to the inclusion of unicode / encoding support. I never really considered the absolute number of files to be an issue. It is a core feature of Cava that files are not compressed and packed at the end of an exec file so you will get a number of files that is roughly equal to the number of files your script may access.

With regard to distribution of Wx based code in general - as already pointed out - why not distribute Perl and use ppm or PAR::Dist to distribute additional code? For cases where you don't wish to do this, for whatever reason - I maintain the Wx::Perl::Packager module and can confirm that complex Wx apps can be wrapped and distributed successfully using

PerlApp
PAR::Packer (using wxpar)
Cava Packager

As noted in a previous reply, the slow running of pp may well be caused by your AV product - I experience this when testing Wx::Perl::Packager against PAR::Packer.

Regards, Mark.