Basically: The systems would PXE boot the bootloader (or maybe it was burned locally to the boot ROM or similar, I don't recall). Then firebreather would spray the kernels and associated boot data over multicast to all the machines at once. Any that were lagging behind or missed packets, would catch them the next time around, firebreather would spray the images a few times or something.
The bigger issue that we faced was that dnsmasq couldn't keep up with all the UDP packets and we had to switch to Kea kind of mid-flight, which was a bit of work since it was a weekend (of course things fail on friday night) and restarting everything to get new leases (and a few with duplicate IPs) was a bit of nail biting. It all sorted itself out though and we haven't had any more issues on that front.
Alpine with lbu[0] seems like a perfect fit and looks IMHO less experimental. Also you can provide backups straight via iPXE[1].
Nonetheless, kudos for the slim ubuntu image :)
There are some issues with this, but overall it works ok. For now, it is just what I ended up with. Total boot download is about 100megs, which isn't too bad... machine is up and running in 60s, which is fine for this workload right now. It does suck rebooting the whole datacenter at once though. ;-)
The lbu stuff looks interesting for sure. I'm not a huge fan of the additional NFS requirement, but I assume that can be worked around. That said, I'm open to changing stuff up and optimizing things further. This is some esoteric stuff and we are hiring. =)