Hi, luther!

I mounted Knoppix 4.0.2 CD with the filemanager. Its mount point was /media/sr0. My HDD was mounted at /media/sda1.
I opened a root terminal and issued
Code:
mkdir -p /media/sda1/knx402/master
cp -a /media/sr0/* /media/sda1/knx402/master
cd /media/sda1/knx402
mv master/boot/isolinux master/KNOPPIX
rm master/KNOPPIX/isolinux/boot.cat
rmdir master/boot
mkisofs -l -r -J -V "KNOPPIX" -o knx402.iso -no-emul-boot -boot-load-size 4 -boot-info-table -b KNOPPIX/isolinux/isolinux.bin -c KNOPPIX/isolinux/boot.cat master
Booting from this new ISO image was impossible. I got an error message from isolinux.

I rebooted Knoppix 7.0.3 CD, mounted my HDD, opened a root terminal and changed to /media/sda1/knx402. I issued
Code:
mkdir master/boot
mv master/KNOPPIX/isolinux master/boot/
mkisofs -l -r -J -V "KNOPPIX" -o knx402.iso -no-emul-boot -boot-load-size 4 -boot-info-table -b boot/isolinux/isolinux.bin -c boot/isolinux/boot.cat master
This time it was possible to boot from this ISO image.

Now I am convinced that isolinux expects the linux image in the directory boot/isolinux, but does not search in another directory like KNOPPIX/isolinux.

After you have booted Knoppix from USB you can use the filemanager to mount your HDD. I suppose it is mounted at /media/sda1.

The bonus DVD can also be mounted using the filemanager. I suppose that you can find its root directory at /media/sr0.

Then I would open a root terminal and issue the following commands.
Code:
mkdir -p /media/sda1/knx402/master
cp -a /media/sr0/KNOPPIX /media/sda1/knx402/master
cd /media/sda1/knx402
mkdir master/boot
mv master/KNOPPIX/isolinux master/boot/
rm master/boot/isolinux/boot.cat
mkisofs -l -r -J -V "KNOPPIX" -o knx402.iso -no-emul-boot -boot-load-size 4 -boot-info-table -b boot/isolinux/isolinux.bin -c boot/isolinux/boot.cat master
Burn the new ISO image on a CD-R and try it out.