One idea - not quite in sync with your discussion, but worth mentioning. Since Utu uses Windows - there is a tool called USB Image Tool. Its available for free from http://www.alexpage.de/usb-image-tool/download/
It makes image of the entire USB including boot sectors and restores it on demand. I use it to back up my Knoppix under Windows. It has an option to compress the image for less space. What I know is, it works well with SD cards too
It can be used to transfer the entire image to another SD card
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