@ utu san

May I ask you a question ?

What was the USP that got you started with Knoppix and is that Unique Selling Point still valid today with Knoppix 6 ?

Help me with some numbers. I can do the math but I have the DVD, not the CD, edition so my numbers are huge.

Code:
du -hs /mnt-system/KNOPPIX
This gives you an upper bound on your current flash file system requirements. Remaster will generate a new KNOPPIX directory so double this first number.

Code:
sudo du -hs /UNIONFS
This gives you an upper bound on the temporary file system space you would need to remaster unless we can find a way of improving on kl522's method for remastering a USB installation.

Add the second number to the (doubled) first number and you get an idea of the minimum size flash file system you will need to do what you want.

I don't think you'll be able to do this on a mere 2 Gb SD card. You might able to do it on a 4 Gb SD card but I think you would have to live with a small (512 Gb) persistent store so you might find you have to 'revise' the KNOPPIX file quite often.

Life would obviously be a lot easier with an 8 Gb SD card but wait a minute.

I've never done an install to HD but I guess the difference between this and an install to USB is that the HD install decompresses the KNOPPIX file. You don't need knoppix-data.img because you can update, add, delete software, tweaks and whatever to your heart's content.

How much file system space might this requires ? At a guess, round about the amount of temporary file system space needed to remaster. I'm guessing you could get that onto a 4 Gb file system and continue to be happyily innocent of remastering.

I'm not trying to suggest this is what you should do, merely suggesting you can't have it always have it all so it's a good idea to think, from time to time, about what is essential for you and what would be merely nice to have.

Now, do you see why I ask what, for you, is the Knoppix 6 USP ?