
2nd I tried building the .iso under linux, accessing the FAT32 files directly, but nada. The iso built but insert wouldn't run (couldn't find it's own file system). My personal Boot images now work

3rd, tried moving the files themselves to the ext2 partition, then mkisofs, nada, no insert (boots still work).
Back to the drawing board <g>, 4th, mounted the original iso as a loopback file, re-extracted the build tree again (simple copy using cp -av) and merged changes from old build tree (boot images, main.scn and custom.scn plus personal sub-dirs, including chmod 555 for all), Bingo! Everything works, best thing since sliced bread!
Ok, next, sleep (lots), mow the grass then customize Insert to include my own config files, etc. <chuckle>. Wish me luck ...
YMMV