Hi gmc
Did you also set the ownership and permissions?
sudo mkdir /mnt/sda1/ezremastertemp
sudo chown tc:staff /mnt/sda1/ezremastertemp
chmod 775 /mnt/sda1/ezremastertemp
And then point the first page ezremaster to that temp directory rather than using the default RAM based /tmp/ezremaster.
I thought I had it set right but did not. I compared the permissions and ownership with the one I created on the external HDD (NTFS) with the one I made on the USB thumb drive (ext2) - they were identical but only the HDD temp storage would work with ezremaster. I wanted to avoid that one because it required the ntfs utility to run, and that used up precious RAM.
Before I got your response I tried starting ezremater from a root console and that part worked. I was then able to use the USB thumb drive for temp storage.
At that point I ran ezremaster again. This time I had a 256MB USB thumb drive formatted as linux swap, a second USB thumb drive (8GB) for temp storage, running as root, monitoring with htop and watch -n 1 cat /proc/swaps.
Using this setup I saw a significant reduction in memory useage - so low that the 256MB swap drive was never touched. RAM swap was only minimally used, generally around 2 or 3 percent.
So, did it work?
No. I still got the same kernel panic when booting the new CD.
But wait! There is good news! I went back tot he wiki and read through the entire article on ezremaster again. (It makes more sense after using it for a while and then reading the guide again.) This time I ran ezremaster again but chose differnet options. Instead of choosing 'Extract TCZ in to initrd' I selectively chose 'Inside initrd' and Inside initrd on boot'.
Success!
Ironically, after re-reading the wiki I realized that extracting TCZ's into the initrd was the worst choice I could have made for booting on these thin clients - they don't have enough memory as it is, they sure don't need more things loaded into RAM at boot time!
Maybe at a later time I will try the 'extract TCZ' method again with the HP T5740 since it has lots of memory.
Anyway - I want to tell you how much I appreciate the time and effort you have put into helping me with this. I have learned so much through the process, thank you. I do have another question or two for follow-up it you don't mind. I'll use another post to keep things separate.