p.s. I just realized MAAAYBE this needs to be moved to TCE
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Currently I have tested the following which may solve the problem and make it stable:
1. I created 2 partitions on a USB - small 80 MB as /mnt/sdb1 and larger 7.2 gig as /mnt/sdb2
2. I put grldr and menu.lst on /mnt/sdb1 - normal place
3. I made a folder on /mnt/sdb2 to hold the 3x install as
/mnt/sdb2/v3x/tce
4. Put files and folders there, such as
/mnt/sdb2/v3x/tce/optional/AllTheTCZfiles.tcz .tcz.md5.txt .tcz.dep etc.
for 3x and
/mnt/sdb2/v3x/tce/ver3x/bzImage and tinycore.gz for booting and
/mnt/sdb2/v3x/tce/onboot.lst
(cont)