This tutorial will show you how to customize and remaster your ubuntu 9.04 jaunty using a jaunty iso file.

1. Create a work directory

mkdir jaunty

2. Create the following directoires

mkdir jaunty/cdrom
mkdir jaunty/tmp
mkdir jaunty/root

3. Mount the jaunty iso image on jaunty/cdrom directory

sudo mount -o loop jaunty.iso jaunty/cdrom

4. Copy everything from the cdrom to jaunty/image directory

cp -r jaunty/cdrom jaunty/image 

5. Now the image directory has the content of your cdrom

We are going to rebuild filesystem.squashfs under jaunty/image/casper

Move the filesystem.squashfs image to jaunty/tmp directory

sudo mv jaunty/image/casper/filesystem.squashfs jaunty/tmp

6. Mount the filesystem.squashfs under jaunty/root direct

sudo mount -o loop jaunty/tmp/filesystem.squashfs jaunty/root

7. Copy the contents of fileystem.squashfs to jaunty/remaster

sudo cp -r jaunty/root jaunty/remaster

8. Copy resolv.conf and sources.list from the host system

cp /etc/resolv.conf jaunty/remaster/etc/

9. Preserve original sources.list.

sudo cp jaunty/remaster/etc/apt/soures.list jaunty/remaster/etc/apt/soures.list.backup
sudo cp /etc/apt/sources.list jaunty/remaster/etc/apt/

Make sure that sources.list points to jaunty archive

10. Now you can chroot to jaunty/remaster

chroot jaunty/remaster

11. Now run the following ( You are inside chroot )

mount /proc
mount /sys
mount -t devpts none /dev/pts

The above commands mount the respective directories inside chroot.

12. Now you can install/remove necessary packages using apt. eg:

apt-get update
apt-get install vlc
apt-get remove gimp

You can update the platform in general by running.

apt-get update
apt-get dist-upgrade -y

13. Cleanup the unwanted files.

apt-get clean
rm -rf /tmp/*
rm /etc/resolv.conf
umount -l -f /proc
umount -l -f /sys
umount /dev/pts

14. Now replace the sources.list with the original sources.list

cp jaunty/remaster/etc/apt/sources.list.backup jaunty/remaster/etc/apt/sources.list

15. Repack squashfs:

mksquashfs remaster image/casper/filesystem.squashfs -e remaster/boot

16. Recreate filesystem.manifest & filesystem.manifest.desktop:

Run the following commands.

chroot remaster dpkg-query -W --showformat='${Package} ${Version}\n' | tee image/casper/filesystem.manifest
cp -v image/casper/filesystem.manifest{,-desktop}
REMOVE='ubiquity casper live-initramfs user-setup discover xresprobe os-prober libdebian-installer4'
for i in $REMOVE
do
sed -i "/${i}/d" image/casper/filesystem.manifest-desktop
done

17. Recreate md5sum

cd image && find . -type f -print0 | xargs -0 md5sum > md5sum.txt

18. Copy filesytem.squashfs manifest to imag dirtorey

Recreate the iso image:

mkisofs -r -V "$IMAGE_NAME" -cache-inodes -J -l -b isolinux/isolinux.bin -c isolinux/boot.cat -no-emul-boot -boot-load-size 4 -boot-info-table -o ../ubuntu-jaunty-remix.iso .
cd ..

Now your remastered ubuntu 9.04 jaunty is achived.

Now install the image on to a hard disk or use it as a liveCD/USB environment for recovery or general use.

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You can also just use Reconstructor

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Source: http://blog.dipinkrishna.info/2009/07/customise-or-remaster-ubuntu-904-jaunty.html