Since I couldn't find anything "hard fact" regarding the bootstrap requirements for the primary partition, I went and ran a few tests. Thus far, no offset is required when building the FAT partition nor are there any specifics (thus far!) as to where (sector) any Pi files are located. Below, $disks is populated by scanning fdisk -l for removable usb media:
for disk in $disks
do
dd if=/dev/zero of=/dev/$disk bs=1M count=2
fdisk /dev/$disk << EOF
(New>Partition1>Start=1,End=14)
(Type>Fat32-LBA>Bootable)
(New>Partition2>Start=15,End=NULL)
(Write)EOF
mkfs.vfat /dev/${disk}1 && mkfs.ext2 /dev/${disk}2
mkdir -p /mnt/${disk}1; mount /dev/${disk}1 /mnt/${disk}1
mkdir -p /mnt/${disk}2; mount /dev/${disk}2 /mnt/${disk}2
cp $source/boot/* /mnt/${disk}1/ -fR
cp $source/data/* /mnt/${disk}2/ -fR
sync; sync; eject /dev/${disk}
done
I kept getting overlaps (Sect. 1-13 for FAT, 13-something for EXT) when DD'ing the Pi7 SSH image which flagged Fdisk errors saying logical sector and physical sector counts mis-matched, which got me to wondering if I'd have problems later down the road. Except my forgetting to implement /etc/resolv.conf the test went through perfectly.