Hmm, could you leave out the least visited articles to reduced the size massively?
Might be better to ignore certain topics you know you're not interested in. (That way if there's no result, you know there's either truly no result, or that you don't care anyway because you're not interested.)
Or perhaps most effective for the size goal would be just to cut images. Perhaps selectively include them depending on category - e.g. maybe you want them for science & technology categorised articles (diagrams) and geography, but can do without otherwise.
> Kiwix also allows you to download subdivisions of wikipedia — like the top 1 million articles at 43.53GB
I’d think the good ol’ Page rank would be a better metric for deciding which ones to prune.