Quote Originally Posted by job317 View Post
1.) When I build the compressed image, I have unmounted /proc and left chroot, right? After leaving chroot, the source "/dev" folder is still populated. Is this expected?
Yes.
2.) How sensitive is the location where the mkisofs commands are executed?
The first mkisofs which makes the compress image is not sensitive to location, as it uses absolute pathnames.

The second mkisofs which makes the boot image ***IS*** sentive to location, as you notice it has the -b & -c, both of them using relative pathnames.
3.) I'm using the create_compressed_fs command provided with the Knoppix 6.2.1 disk yet I saw some comments regarding a newer version. Shouldn't the one that came with the disk be sufficient?
Should be adequate.
4.) What kind of troubleshooting should I try next? e.g. Is there a test script to run on the KNOPPIX image or the final ISO to test integrity?
I thought using qemu is already a very good tool to test. You can try to add cheatcode 'debug' and see if it will display additional information.

By the way, what kind of file system are you building the remaster image on ? Remember VFAT is bad !