Hi all,

Last year I remastered Knoppix 4.0.2 to add some apps needed to set up a demo, and it was a great success. This year I have something slightly different I need to do. The long and short of it is that I need to modify Knoppix 5.0.1 (CD edition), but all I need to do initially is make some changes to the config files on the CD.

I've been following the procedure on the wiki page at http://www.knoppix.net/wiki/Knoppix_Remastering_Howto

It all seems fairly straightforward - as I'm happy with the config changes I'm making, I'm not even performing a chroot - basically I've just copied out the contents of /KNOPPIX, changed the files I need, then attempted to rebuild.

However when I rebuild the CD, it's too big and won't fit on a CD any more.

The first thing I've noticed is that when I copy /KNOPPIX out to my hard disk (ext3 parition mounted as /mnt/sda1), du reports it is bigger than the original:
Code:
root@3[source]# du -sb /mnt/sda1/source/KNOPPIX/
1975775659      /mnt/sda1/source/KNOPPIX/
root@4[KNOPPIX]# du -sb /KNOPPIX/
1967972624      /KNOPPIX/
So straight off my copy of the KNOPPIX file contents is 10MB bigger than the mounted copy at /KNOPPIX. The config file edits add virtually no size to the data. Now when I rebuild the KNOPPIX file it comes out as 723MB. The original file from the CD is reported as 693MB, so I've gained 30MB without adding any files. (sizes reported using ls -lh)

I ran create_compressed_fs overnight with the -b option in case that was responsible, but after 10 hours of processing it came to 722MB.

I've read some posts on the forum saying that this is quite a common problem, and although I think I understand the reasons behind these posts I haven't chroot'ed into my copy of the KNOPPIX data, and haven't mounted anything under it.

Here's my build command for your reference (it's a copy and paste from the Wiki):
Code:
mkisofs -R -U -V "KNOPPIX.net filesystem" -publisher "KNOPPIX www.knoppix.net" \
     -hide-rr-moved -cache-inodes -no-bak -pad /mnt/hda1/knx/source/KNOPPIX \
  | nice -5 /usr/bin/create_compressed_fs - 65536 > /mnt/hda1/knx/master/KNOPPIX/KNOPPIX
I must be missing something, or doing something wrong - please can someone help me with this? I'm so close to home now - I've checked the ISO out in VMWare and it works as I want it to - it's just bigger than a CD which is a real problem for the application I have in mind - DVD is not an option.

Thanks in advance for your help,

sparky