what I (was) planning on doing is installing some stuff on other data.img's. They could be on another storage medium and can be used by mounting the other servers.
I also don't get why the image is full you say you have a 115gb hard disk, that can't possibly be filled all the way
you can also switch squashfs? thats compressed a tad bit better.

and I've heard some things about knoppix 64 bit? there is a topic about that somewhere