Tried again to install TC. With Ubuntu workstation (Ubuntu is current distro, transition to Debian is going...) need DVD setup disk for USB, too.
I found documentation (yes, I make docs...) and bunch of non-working USB-boot sticks from my previous attempt to make bootable USB-stick. I have some experience with embedded environments with Uboot and linux static drivers, but same methods are not working with Legacy BIOS, extlinux, static kernel drivers and udev -system. There is some mystical bug on USB-bridge setup, which terminate boot process. USB-boot is known to work with win and grub2, so there must be solution for that.
But there is lot of other isssues: I think boot process and driver installation should be totally different. TC is pro system, and pro's want to control things, especially drivers which are serious security problem (=runs at system level permissions).
I will try this kind of system:
1) Debian, network connection and 2 USB sticks. One stick (INS-stick) for installation and drivers database and one stick (OU-stick) for "operative use". On OU-stick is only those drivers, which are actually needed.
2) Both sticks: Formatting and partitioning with standard tools fdisk/cdisk. File format for current PC-BIOS boot (typically Win95 FAT32 LBA)). Create small boot partition for grub2 code.
3) Both sticks: Mrb.bin/GPT settings (boot bit, jump vector to boot partition (=Grub2 code), etc.), and file copy (=dd) for grub2 code to boot partition)
4) Both sticks: Stand alone grub2 boot to test boot USB-stick boot (if, succeed, you have limited kernel, drivers and command set to work with). I'm not (yet) familiar with Grub2, but seems to me that available disks and other boot media is visible, and you can boot Grub at "/boot" directory at boot partition, at leas temporary. Typically system crashes when trying to start kernel at new permanent filesystem location. No single message is available if crash, so it it impossible to find out what was wrong. It is lot easier ot try-and-error just Grub2 boot than whole system.
5) INS-stick: load TC-command line version to main partition "/"
6) Boot on TC with INS-stick, put OP-stick on other USP-port
7) Load full TC with drivers, GUI, Xorg, etc, to OP-stick on several phases and try boot on OP-stick on every phase
8)If OP-stick is working, set INS-stick for system rescue stick (drivers etc.)