Thanks.
I'll have to look at grub efi if it can load 32bit kernel from its 64bit efi. I'll also have to deal with the video resolution somehow. The program I run has a text ui (mostly text, some lines, one write directly to the framebuffer for my 'splash' screen), and I check the console dimensions and adjust accordingly, but with uefi I end up with way too much space and it looks a little silly. (Although I guess I could just center what I have into the middle of the screen instead of adjusting/fitting to actual console resolution).
I'll describe what I currently do to be a little clearer-
download vmlinuz, core.gz (from x86/release/distribution_files/)
extract core.gz, remove lots of stuff, change some files, create my own init, add a program, etc. (all scripted)
(at this point I get a kernel, root fs, busybox, some libraries, a couple modules- without having to compile it myself- this is about the only distro I can figure out whats going on from start to finish)
now pack my core files back up to core.gz
use mkisofs to create an iso (using isolinux.bin, config file, ldlinux.c32)
use isohybrid to make it usable as both an iso or a dd image to flash
At this point I'm really good to go, and have booted many pc's (usually using flash drive, unless an old pc that doesn't boot usb, then I use cd). With Windows 8+ pc's, I have to turn off secure boot and enable csm, boot my drive, do my thing, put settings back. If I get uefi booting to work, I still have to disable secure boot, but don't have to also find out where they hid the csm settings (I have also seen pc's where they 'forgot' to put in the csm option, requiring a firmware update).
other notes-
uefi can boot the kernel directly (same bitness only it seems), but it is not of much use unless you also pack initramfs inside the kernel, as you are then booting the kernel with no commandline options
syslinux efi, from what I can gather, will only boot same bitness kernels (if I'm reading its source code correctly- it takes me a week of studying to understand what's going on, and only a day or two to forget what I figured out)
I'll have to get a uefi firmware for qemu so I can try some more things without actual uefi hardware