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+Download Ubuntu Hardy Heron iso (or whatever version you want).
+Download {{:howtos:unetbootin-linux-216.zip|unetbootin-linux-216.zip}} (find the newest version here: http://unetbootin.sourceforge.net/
+Format your usb pen with fat32.
+Make LiveUSB with unetbootin (just unpack unetbootin-linux-216.zip and execute unetbootin as root) or use the usb-builder tool within Ubuntu.
+===== Version 1 =====
+<code>
+sudo mount -o loop -t squashfs /media/disk/casper/filesystem.squashfs /home/tdd/No-rsync-stuff/usb
+sudo mkdir /tmp/ubuntu_usb_image
+sudo cp -aR /home/tdd/No-rsync-stuff/usb/* /tmp/ubuntu_usb_image/
+sudo mount -t proc none /tmp/ubuntu_usb_image/proc
+sudo mount -o bind /dev /tmp/ubuntu_usb_image/dev
+sudo chroot /tmp/ubuntu_usb_image /bin/bash
+</code>
+Inside chroot edit /etc/apt/sources.list to enable the repositories you need and insert a dns server into /etc/resolv.conf. If you don't do this you can't download anything through apt-get.
+To choose a different keyboard layout:
+<code>
+apt-get install console-data
+dpkg-reconfigure console-data
+</code>
+Make you apt-get install's and configurations.....
+Start rebuilding the LiveUSB:
+<code>
+cd /tmp
+sudo umount /tmp/ubuntu_usb_image/proc
+sudo mksquashfs ubuntu_usb_image ubuntu_usb.squashfs -no-sparse
+sudo cp ubuntu_usb.squashfs /media/disk/casper/filesystem.squashfs
+</code>
+===== Version 2 =====
+This is more or less copied from https://wiki.ubuntu.com/MobileTeam/Mobile/HowTo/ImageModification. The difference is that my source is a build and ready usb stick and not an image file.
+I also found it necessary to give tmpfs an upper size of 2GB, otherwise it ran out of space during updates.
+===== The manual way =====
+  * Preparation:
+<code>
+mkdir /tmp/squashfs
+mkdir /tmp/tmpfs
+mkdir /tmp/mergemount
+</code>
+  * Mount the filesystems:
+<code>
+sudo modprobe unionfs
+sudo mount -o loop -t squashfs <mount point for usb>/casper/filesystem.squashfs /tmp/squashfs
+sudo mount -o size=2G -t tmpfs tmpfs /tmp/tmpfs
+sudo mount -t unionfs -o dirs=/tmp/tmpfs:/tmp/squashfs=ro none /tmp/mergemount
+</code>
+  * Make sure essential filesystems are mounted inside the image:
+<code>
+sudo chroot /tmp/mergemount mount -t proc proc /proc
+sudo chroot /tmp/mergemount mount -t sysfs sysfs /sys
+sudo chroot /tmp/mergemount mkdir -p /dev/pts
+sudo chroot /tmp/mergemount mount -t devpts devpts -o noexec,nosuid,gid=5,mode=620 /dev/pts
+</code>
+Make sure packagelists are up to date and install the software you like:
+<code>
+LANG=C sudo chroot /tmp/mergemount apt-get update
+LANG=C sudo chroot /tmp/mergemount apt-get install <your desired package>
+</code>
+  * Clean up:
+<code>
+sudo chroot /tmp/mergemount apt-get clean
+sudo chroot /tmp/mergemount umount /proc
+sudo chroot /tmp/mergemount umount /sys
+sudo chroot /tmp/mergemount umount /dev/pts
+sudo chroot /tmp/mergemount rm -rf /dev/pts
+</code>
+  * Build a new squashfs with your changes:
+<code>
+sudo mksquashfs /tmp/mergemount /tmp/filesystem.squashfs
+</code>
+  * Clean up the temporary mountpoints:
+<code>
+sudo umount /tmp/mergemount
+sudo umount /tmp/tmpfs
+sudo umount /tmp/squashfs
+</code>
+  * Copy the new squashfs in place:
+<code>
+sudo cp /tmp/filesystem.squashfs <usb mount point>/image/casper/
+</code>
+  * Clean up the rest:
+<code>
+sudo rm -rf /tmp/tmpfs /tmp/squashfs /tmp/mergemount /tmp/filesystem.squashfs
+</code>
+Have fun with your changed imagefile ....
+===== The same as shellscript =====
+The script below uses the same setup as above and spawns a rootshell inside the squashfs, you can then run "apt-get update" and install your package or make other changes, if you exit the shell with Ctrl-D or the 'exit' command it will offer you to re-roll the squashfs for you.
+<file>
+#!/bin/sh
+if [ -z $1 ];then
+    echo 'I need a path to the usb mount point as first argument'
+    exit 0
+fi
+SQUASHFS=/home/tdd/tmp/squashfs
+TMPFS=/home/tdd/tmp/tmpfs
+MERGEMOUNT=/home/tdd/tmp/mergemount
+SQUASHFSFILE=/home/tdd/tmp
+mkdir $SQUASHFSFILE
+mkdir $SQUASHFS
+mkdir $TMPFS
+mkdir $MERGEMOUNT
+sudo modprobe unionfs
+sudo mount -o loop -t squashfs $1/casper/filesystem.squashfs $SQUASHFS
+sudo mount -o size=3G -t tmpfs tmpfs $TMPFS
+sudo mount -t unionfs -o dirs=$TMPFS:$SQUASHFS=ro none $MERGEMOUNT
+sudo chroot $MERGEMOUNT mount -t proc proc /proc
+sudo chroot $MERGEMOUNT mount -t sysfs sysfs /sys
+sudo chroot $MERGEMOUNT mkdir -p /dev/pts
+sudo chroot $MERGEMOUNT mount -t devpts devpts -o noexec,nosuid,gid=5,mode=620 /dev/pts
+sudo cp /etc/resolv.conf $MERGEMOUNT/etc/
+LANG=C sudo chroot $MERGEMOUNT
+sudo chroot $MERGEMOUNT rm /etc/resolv.conf
+sudo chroot $MERGEMOUNT umount /proc
+sudo chroot $MERGEMOUNT umount /sys
+sudo chroot $MERGEMOUNT umount /dev/pts
+sudo chroot $MERGEMOUNT rm -rf /dev/pts
+echo -n 'do you want to build a squashfs with the changes ? (y/n) '
+read yesno
+if [ -z $yesno ];then
+    yesno='n'
+fi
+if [ $yesno = 'y' ];then
+    sudo mksquashfs $MERGEMOUNT $SQUASHFSFILE/filesystem.squashfs -wildcards -e proc/*
+fi
+sudo umount -t unionfs $MERGEMOUNT
+sudo umount -t tmpfs $TMPFS
+sudo umount -t squashfs $SQUASHFS
+if [ $yesno = 'y' ];then
+    sudo cp $SQUASHFSFILE/filesystem.squashfs $1/casper/
+fi
+echo -n 'do you want to cleanup in /tmp ? (y/n) '
+read yesno
+if [ -z $yesno ];then
+    yesno='n'
+fi
+if [ $yesno = 'y' ];then
+sudo rm -rf $TMPFS $SQUASHFS $MERGEMOUNT $SQUASHFSFILE/filesystem.squashfs
+fi
+</file>
+===== Important Notes =====
+For unknown reasons the three mounted filesystems (tmpfs, squashfs and proc) are always lock by something, thus the cleanup phase will not work. I can only get it of by rebooting the computer (fairly annoying!). Because of the locks I was forced to include an exclude statement not digging into /proc.