... in the meantime I thought about your question once more. And I found
4. repeat installation and purge of all programs and tools within the chroot jail, as you did within your HD Installation (it's your job)
isn't necessary and we can jump over
2. a decompresses filesystem image at '/opt/knx/remaster' (will be done by the scripts)
We have to rsync most of the HD Installation to '/opt/knx/remaster' and this is the easiest way to obtain the remastered version of Knoppix

In the next days I'll test, which directories we have to exclude in the rsync process (at least '/opt/knx', '/proc', '/mnt', '/media' and so on) and I'll offer a new version of my scripts (also the recombine scripts).

Greetings Werner * http://www.wp-schulz.de/knoppix/summary.html
Own Rescue-CD with Knoppix (Knoppix V6.7.0 remaster)