confused by password stuff

[klaus2008]

I guess since Knoppix uses FAT32 - the biggest I can make it is ~2GB...

If your flash device uses FAT32 then your maximum size of single file is 4 GB.

So I gave it a file size during boot in the option to make a persistent settings store file

You have to enter only the integer. The size of the persistent image file is calculated in chunks with a size of 1 MB. Example: If you want to use a persistent image file with a size of 4000 MB then you must enter 4000.