How to Remaster a Puppy Linux ISO File Manually

• copy the existing file system to a working directory, e.g. for a frugal installation:

  mkdir -p /mnt/home/workingdirectory

  cp -a  /initrd/pup_ro2/* /mnt/home/workingdirectory

• modify the contents of the working directory to one's requirements, e.g. by inspecting the contents of the personal storage (save) file (either /initrd/pup_rw for pupmode 12 or /initrd/pup_ro1 for pupmode 13) and then copying from there the directories /etc, /root, /usr and /var
  [WARNING: if the ISO file is for wide distribution one must be selective as to what is copied from those directories]
  
  
• create the SFS file of the modified file system, e.g.:

  mkdir -p /mnt/home/remasterdirectory

  cd /mnt/home

  mksquashfs workingdirectory remasterdirectory/puppyremaster.sfs -noappend

• copy any necessary files to /mnt/home/remasterdirectory from the original ISO file (or optical disc) so as to create a complete and new ISO file:
  [TIP: a recent version of the boot-loader system file isolinux.bin is highly recommended]
  

  cd /mnt/home

  mkisofs -b isolinux.bin -c boot.cat -D -l -R -v -V "Puppy Linux remaster" -no-emul-boot -boot-load-size 4 -boot-info-table -o "newpuppy.iso" remasterdirectory

• (optional) write (burn) the ISO file to optical disc

Additional Reading