Hi folks, I'll try to be as brief as possible and hope this thread consolidates the issues on booting process for 3.4 remastering.

Here is the setup (following the howto convention) I've hd-installed 3.4 and doing the remastering on the hd

Source tree:
mkdir /mnt/sdb2/knx/source
mkdir /mnt/sdb2/knx/source/KNOPPIX
cp -pR /cdrom/boot /mnt/sdb2/knx/source/

since booted from the hd, the cdrom does not contain the rootfs. Copy the compressed file to disk
cp /cdrom/KNOPPIX/KNOPPIX /mnt/sdb2/knx

Create a folder to mount
mkdir /mnt/sdb2/compressed

Load cloop and mount the compressed FS
insmod cloop file=/mnt/sdb2/knx/KNOPPIX
mount -o ro /dev/cloop /mnt/sdb2/knx/compressed/

Copy everything from compressed fs to source tree under KNOPPIX
cp -pR /compressed/ /mnt/sdb2/knx/source/KNOPPIX/

Now chroot to /mnt/sdb2/knx/source/KNOPPIX
if /dev/null errors occur, go edit fstab and add suid to mount options for /mnt/sdb2/ (in my case) This is covered in the Howto.

RootFS coppied unmount it.
umount /mnt/sdb2/knx/compressed.
rmmod cloop.

Now we have
/mnt/sdb2/knx/source/boot
/mnt/sdb2/knx/source/boot/isolinux/ (and files there)
/mnt/sdb2/knx/source/KNOPPIX/ (the root file system with /boot, /etc, /usr... etc etc)

Create a placeholder for remastered cd
mkdir /mnt/sdb2/knx/master

copy boot from cdrom
cp -pR /cdrom/boot /mnt/sdb2/knx/master/

create KNOPPIX root
mkdir /mnt/sdb2/knx/master/KNOPPIX
and with mc copy everything from /cdrom/KNOPPIX/ to /mnt/sdb2/knx/master/KNOPPIX/ except that ~700MB KNOPPIX file.

Assuming that we have done remastering installed and uninstalled programs in the chroot of /mnt/sdb2/knx/source/KNOPPIX which I did not do to see if everything will be ok at the first place so I did not touch anything yet.

We now have to create the compressed file KNOPPIX from source to master. (right?)
The command for that is
mkisofs -R -U -V "KNOPPIX.net filesystem" -P "KNOPPIX www.knoppix.net" -hide-rr-moved -cache-inodes -no-bak -pad /mnt/sdb2/knx/source/KNOPPIX | nice -5 /usr/bin/create_compressed_fs - 65536 >/mnt/sdb2/knx/master/KNOPPIX/KNOPPIX

Go and verify you have the large file in /mnt/sdb2/knx/master/KNOPPIX/KNOPPIX

Now we will create the CD iso. with boot sector.
cd /mnt/sdb2/knx/master/
mkisofs -pad -l -r -J -v -V "KNOPPIX" -no-emul-boot -boot-load-size 4 -boot-info-table -b boot/isolinux/isolinux.bin -c boot/isolinux/boot.cat -hide-rr-moved -o /mnt/sdb2/knx/knoppix.iso /mnt/sdb2/knx/master

After a while we'll end up with knoppix.iso in /mnt/sdb2/knx/
Burn it and boot with it.

Here comes the problem. After booting The screen says

ISOLNUX 2.04 (Debian, ...date..) (version info and author...)
Could not find kernel image: linux
boot:

Any thoughts?

I didn't touch the miniroots under /boot/isolinux namely minirt24.gz and minirt26.gz Which I would like to customize too. But I could not create a bootable cd at the fisrt place.
Is there anything I'm missing.

Any help is appreciated.
Cheers.