I have built a great USB executable version of KNOPPIX 5.11 following the directions at USB Knoppix 5.1.1 install | USB Pen Drive Linux and it worked great but I couln't get the live DVD to load to a USB drive then I mounted the drive through the root and still could not get it to rsync properly to build a new flash.

I'll keep using my live cd version but the DVD has a lot more stuff....