A Fat32 format should work just fine and Knoppix 3.9 is the same version I'm running. you might try
That will atleast let you take a look at you drive and what format it is. AAHH!! I just noticed that in your first post you said you were trying mount /dev/sda1. For whatever reason, I had to use /dev/
uba1, as that's what Knoppix was assigning to my thumb drive. You might want to give that a shot. Once you get your configs and your home directory setup on your USB drive, you'll just have to run this at boot...
Code:
boot: knoppix home=/dev/uba1 myconfig=/dev/uba1