tnx for the pointer to remastersys. here are the details for any other linux noobs like me.
remastersys is not included in bt5. I have to install it.
I went to install it to my current bt5 install this way:
nano /etc/apt/sources.list
add the following line
deb
http://www.geekconnection.org/remastersys/repository karmic/
(this particular repository for For Karmic, Lucid and Newer with grub2 - version 2.0.13-1 and up)
then
apt-get update
then
remastersys backup
well, it starts out ok but there is a cryptic error
cannot create regular file '/home/postgres/Desktop' : No such file or directory
but it keeps going and seems like it's going to work but then i get these 2 lines over and over
[number] aufs au_xino_do_write:381

ostgres[1822]: I/O error write failed (4294967268)
[number + ~.006] aufs au_xino_do_write:417

ostgres[1822]: I/O error write failed (-5)
Not even control -c or a soft reset will stop this runaway train. I have to power down to reboot.
I am guessing that it's trying to backup the system to the usb stick but cannot-maybe because there is no real directory structure on the usb stick-just a squashfs file.
So I rebooted, reinstalled remastersys,mounted my hard drive this way
mkdir /mnt/win
mount /dev/sdc1 /mnt/win
and did
remastersys backup /mnt/win/custom.iso
SAME PROBLEM! I look on my hard drive and find
custom.iso.md5 but obviously no iso
now what?