Send in the Clones

[klaus2008]

I would create a directory on the hard disk and copy the persistent image from the first SD card to that directory. Afterwards I would boot Knoppix from CD and do a flash install on the second SD card. Then I would copy the persistent image from the hard disk to the KNOPPIX directory on the second SD card. The two SD cards should be identical.

[krishna.murphy]

I would create a directory on the hard disk and copy the persistent image from the first SD card to that directory. Afterwards I would boot Knoppix from CD and do a flash install on the second SD card. Then I would copy the persistent image from the hard disk to the KNOPPIX directory on the second SD card. The two SD cards should be identical.

Yes, this would certainly work, too. If your CD is slow, though, it would probably be faster to do it from the first flash drive, as I described. And the caveat about the filesystem remains. One option is to create another partition for Knoppix, and/or a swap partition (using GParted, probably.)

Cheers!
Krishna