Thanks polikuo
Your examples have worked perfectly.
I'll document 'here' exactly what I did to remaster a stock Core-9.0.iso file and integrate a few boots codes.
Setup basic VirtualBox virtual Machine (setting network to 'bridged', setting storage/optical drive to 'Core-9.0.iso')
Boot up vm
copy Core-9.0.iso to usb flash drive
attach usb flash drive to my vm
mount the usb flash drive in vm using $ mount /mnt/sdb1
installed mkisofs-tools
$ tce-load -wi mkisofs-tools
Executed the following commands as per your example
tc@box:/tmp$ mkdir /mnt/CD /tmp/cdroot
tc@box:/tmp$ sudo mount /mnt/sdb1/Core-9.0.iso /mnt/CD
tc@box:/tmp$ cp -r /mnt/CD/boot /tmp/cdroot
tc@box:/tmp$ chmod +w /tmp/cdroot/boot/isolinux/isolinux.cfg
tc@box:/tmp$ vi /tmp/cdroot/boot/isolinux/isolinux.cfg
...
append loglevel=3 syslog waitusb=5 nodhcp noautologin showapps noutc tz=EST-10 cron
...
# I also altered the timeout option to make bootup quicker
timeout 30
Save and exit vi
I ran your example to repackage the iso exactly and it works just fine.
sudo mkisofs -l -J -R -no-emul-boot \
-V TC-custom \
-boot-load-size 4 -boot-info-table \
-b boot/isolinux/isolinux.bin \
-c boot/isolinux/boot.cat -quiet -r \
-o output.iso /tmp/cdroot/
copied output.iso to usb flash drive
$ cp output.iso /mnt/sdb1
$ sudo umount /mnt/sdb1
ejected the usb flash drive from the vm using virtualbox interface
Windows kindly detected and auto mounted the drive to its fs
copied output.iso to local fs
selected output.iso as a virtual cd for boot up in VirtualBox vm storage settings
booted vm and all boot codes are now integrated to the iso.
Thanks
[EDIT[: Fixed typo. Changed not to now. Rich