Lukas,
I just read through your document at
http://www.trash.net/~lkarrer/projects/solcdburn/solcdburn.html

I am in a similar situation except that I am moving from 2.5.1 to 2.7 for
the OS.  As you mentioned, the CD layout has changed dramatically in the
mean time.  I used to use a product from Sun called RE-Toolkit which has
been slimmed down and renamed to CDTK.  Just wondering if you had ever used
that product.

My steps are as follows:

Rip source CD to ufs file system

Insert my modifications (ie: I exit suninstall to go to my own install
script which uses a menu driven interface to pre condition the target server
for disk partitioning, and file system building, and I place ufsdump images
of my final file systems which include end state software, etc.)

Use my third party software (Young Minds makedisc in my case) to convert the
image to include Rock Ridge extensions

Run the CDTK tool to recreate the slice map, vtoc, etc.

dump it all to my cd burner.



Your document is solid, yet complicated.  You may be interested in CDTK.

--Dan Solero
  AT&T