So heres how to create your 1MB file:-
Get X2 BIOS manager and open it. You will see four grey sections on the right. This represents the four 256KB sections that make up your 1MB bios file. To use 2x256KB bioses, you must load each bios twice into either half. For example, the following pic shows how you would load 2 4977 bioses into X2 manager to make bank1 load 4977 with a green LED and bank2 load 4977 with a red LED:-

To load the bioses into each 256KB section just click on the section to highlight it and click 'import'.
Make sure the image size is set to 1024K to create a 1 MB file. Now click 'save' under 'image options' to creat your image file. Give it a meaningful name, so you know what the hell it is in future.
Now to flash the chip:
Make sure flash protection is disabled on your modchip and bank1 is selected. (switch your xbox off before doing this)
All you need to do now is FTP to your xbox and copy your new image file into C:bios and reboot evox.
Go to the Flash Bios option in evox and select your newly made 1mb bios file. Wait for Evox to flash the chip and power off your xbox.
You should now have 2 bioses loaded onto your modchip.
NOTES: Using xflash you can flash one bank at a time, this tut was written for evox users, and this method should also work for people with a 1MB flashed TSOP with a 2 bank switch installed. You can have any 2 bioses you want, one could be the 4977 bios and the other original MS bios (good for TSOPs and xbox live)
Good Luck!!!
Edit:- Thanks for the correction neo-dilly.