[link|http://www.knoppix.net/wiki/Knoppix_Remastering_Howto|http://www.knoppix.n...Remastering_Howto] details the remastering procedure. There are others to be found on Google.

But in order to get the thing to fit on a CD you'll just have to dump a truckload of the packages once you get into the chroot environment.

Warning: we did just that at work today and in the process discovered that there is a missing reverse dependency on the emacs21-bin-common package and the rest of the emacs21 packages. apt-get then throws fits and refuses to remove anything else until the emacs problem is fixed. Trouble is that two other packages (auctex is one, IIRC psgml is the other) then refuse to uninstall because they try to write into non-existent directories. Creating the missing directories and running apt-get -f remove fixed the lot, but there may be other landmines...