An addendum to that, I just created an image for a flash drive and it turned out to be about 1GB in size (330MB compressed). openSUSE 11.1, GNOME, BZFlag, and a BZFlag logo at boot. Autologin with "TankCommander" as a user and access to BZFlag from there.
It could probably be trimmed down some. Use of a different window manager would allow greater customization and speed. I'd be happy to give a copy to folks or take suggestions if this is still an active idea.




