I really am ignorant when it comes to setting up embedded stuff, etc.
But, check this out, I have a tc-1.4.3 usb and I made some "flavor" packs for it too.
The "flavors" are actually qemu-img virtual hard drives with tinycore apps/backups inside
awesome thing about tinycore is it can mount these vhd's using a bootcode and restore apps, etc from them.bootcode "tcvd="
i made a flavor named compilr that is loaded with most apps for hacking tinycore, etc.
Simply download tc-usb and compilr flavor, place compilr flavor in "flavors" folder in the usb download(boot and flavor folder inside)
Next, check menu.lst or syslinux.cfg to make sure it all points to your usb.
if your usb is sda1, it's already setup, if other you may have to edit.
below is part of the menu.lst inside, only thing you might have to edit is "sda1"
## For remastering and hacking Tinycore and other distro's too!
kernel /boot/bzImage quiet tcvd=sda1/flavors/compilr restore=tcvd tce=tcvd waitusb=5
The usb is made for either fat16/32 usb using syslinux or ext2/3 usb using grub.
note the vhd's may de-compress to 500MB+
troubleshooting, it is best to choose the "base norestore" option first,
boo to the desktop, open a root terminal and type "fdisk -l"
That will tell you how tc recognizes your usb, if it says it's sdb1 then
edit either syslinux.cfg or menu.lst to point to sdb1.
Then after editing either reboot and choose the option for tcvd on sdb1
here is a entry from the tcvd.cfg which is a sub-menu of syslinux.cfg I made
menu label ^TCVD-2-SDA1
append initrd=/boot/tinycore.gz quiet desktop=jwm tcvd=sda1/flavors/ restore=tcvd tce=tcvd waitusb=5
Very big note, I made this to be edited!
you must add the tcvd name after "tcvd=sda1/flavors"
so if usb is sdb1 and using compilr flavor it would be
"tcvd=sdb1/flavors/compilr restore=tcvd tce=tcvd waitusb=5"