Deleting the first 80 bytes did the trick. I thought that changing the size of the rom would throw off the address values.
Now it loads the ROM and i can change tracks. I can't play the song by hitting any buttons, but my understanding is that famislayer requires some kind of constant clock pulse, not just me hitting play.

Good Deal. Yea, a single trigger will only play a single frame of the NSF file, The NSF Player is called at a 60Hz rate so you wouldn't be able to trigger the play back too well by 'Hand".
Yogi

Doesn't seem to be much documentation out there. I tried and failed, here are the steps i took.

1. Compose music in famitracker and export it as "track01.nsf" ( i have NTSC selected, not sure if that matters)

2. Open "track01.nsf" with Nestopia, it sounds good. Go to View --> "Image info" and take note of the load, init, and play values. For my track the values are
Load Address:   0xA801
Init Address:   0xAA55
Play Address:   0xAA58

3.Removing the header. Open "track01.nsf with a hex editor. I am using HxD. Configure it to show 16 bytes per row ( this makes it visually easier). Replace all bytes before 00000080 with "00". And save it as "temp.nsf"

You need to Delete these 80 bytes not replace with $00

???? never seen that ?????

Is the .NES 41k? Should be 33k PRG (32K PRG+ <1K Header+ 8k CHR). But try removing the Header rather that clearing, I think that's you prob.
Also your NSF MUST be less then 30K and not bankingswiching.
Yogi

1. Compose music in famitracker and export it as "track01.nsf" ( i have NTSC selected, not sure if that matters)

2. Open "track01.nsf" with Nestopia, it sounds good. Go to View --> "Image info" and take note of the load, init, and play values. For my track the values are
Load Address:   0xA801
Init Address:   0xAA55
Play Address:   0xAA58

3.Removing the header. Open "track01.nsf with a hex editor. I am using HxD. Configure it to show 16 bytes per row ( this makes it visually easier). Replace all bytes before 00000080 with "00". And save it as "temp.nsf"

4. Open Famislayer.asm with a text editor. Replace the value of the first three variables with the values noted earlier.
LoadAddy = $a801        ;NSF VARIABLES  (SAME AS VEGAPLAY)
InitAddy = $aa55
PlayAddy = $aa58

5. Place "temp.nsf" in the famislayer directory and run compile.bat.

6. The resulting Famislayer.nes rom should contain your music.

But it doesn't work for me. When i open it with Nestopia i get an error that says "CPU jam!"
Does my NSF not comply with NES?
Is it because i am on 64bit Win7?
Any help is appreciated.
Need to get this process down before a drop the money on a Powerpak