Re-master your flash installation

[kl522]

# cd ..
# mkisofs -R -U -V "KNOPPIX.net filesystem" -publisher "KNOPPIX www.knoppix.net" \
-hide-rr-moved -cache-inodes -pad /lots_of_free_space/source/KNOPPIX \
| nice -5 /usr/bin/create_compressed_fs - 262144 > /lots_of_free_space/master/KNOPPIX/KNOPPIX

After a long time, you will get a compressed image at /lots_of_free_space/master/KNOPPIX/KNOPPIX,
which you can use it to replace your /mnt-system/KNOPPIX/KNOPPIX.

Maybe I was too agressive with the blocksize 262144 ? Most web site only recommends 65536.
I suspect blocksize 262144 might be related to some intermittent problem which I am facing.