I did reply to the PM but rather than have it rot in my PM folder:
Most people who mess with SDAT files (including myself) will attempt to modify the file as little as possible so as to dodge the need to rebuild it. This usually means either having a simple pointer recalculation method, using smaller files or sticking the files at the end of the SDAT and pointing there instead (fairly standard text hacking methods tweaked for SDAT).
SDAT spec if you did not already have it: http://kiwi.ds.googlepages.com/sdat.html
See also sdat posts in the DS rom hacking section as the simple methods apply here too.
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