Ok, so, I have been playing around with Syslinux/ISOLinux, and a distribution called Slax linux. Although Slax was once based on the old defunct Slackware, it is now based on Debian Linux. I have managed to update the bundled Syslinux, and added and configured UEFI boot for it.
Slax has a few features that would be helpful to TechSuite for a Bootable tool:
1st: it has an optional folder, called "rootcopy". Basically, any files you place in here, get copied to the root of the booted linux filesystem in RAM. This would be quite useful for copying the technician auth info from the USB filesystem into the AUFS without needing to remount the USB post boot.
2nd: Slax uses "Slax Modules", so you can add your changes to Slax in a new file, without having to modify or remaster the existing "core" files. In other words, once Ian and his team are finished, the result would be a completely separate file, that is just "dropped into" a core Slax distro.
3rd: Slax allows installing onto a USB drive with existing files - No Formatting required!! Note, that I have made changes to the original Slax folder structure, but I haven't yet updated this feature to reflect my changes. (This feature is normally executed by running a windows batch file. I haven't updated the stock one from Slax just yet).
If anyone would like a copy, please send me a private message. Note, that this does NOT have anything from TechSuite loaded. It is just my customized Slax copy, with my added UEFI capabilities.