I'm trying to create a retina ready version of my application's icon. The application targets 10.5+. I'm using Uli Kusterer's oldiconutil to post process the .icns file I make from a .iconset using iconutil on 10.8. The problem is that if I include a 1024x1024 icon ("icon_512x512@2x.png"), the icon does not display on 10.5. Finder doesn't display the icon, and when it is opened in Icon Composer on 10.5, it appears to be blank/empty. If I remove this largest size, the icon displays correctly on 10.5. Interestingly, if I substitute a completely different, simpler 1024x1024 image with a much smaller file size (~300K instead of ~1MB), the icon again works fine on 10.5. So it seems that there may be some limit on the file size of the overall .icns file and/or the individual image chunks in a .icns file that when exceeded breaks compatibility with Leopard.
Compressing the 1024x1024 image with TinyPNG was not enough to fix the problem. It did result in a significantly smaller .icns file before running it through oldiconutil, but the final, JPEG2000 compressed output of oldiconutil was still much larger than the variant using a simpler substitute image, presumably because the more complicated image is simply not as compressible.
Has anyone else run into this problem before? Have you found a solution? If I can't figure out a solution, I'll have to just omit a retina ready application icon until I drop support for 10.5.