Hi!
I have an always-in SD card, I'm storing everything personal/custom on it in the following way:
I have a directory in /mnt/card called "myhome". I have a small script in /usr/bin with the following content:
startup.sh:
mount -o bind /mnt/card/myhome /home/root
This binds it to /home/root so everything is working fine (not so when you just symlink it)
So I login, type in "startup.sh", logout, login (so my custom .bashrc can be used) and everything's fine. I also link out my custom config files from this dir, so they don't need to be gathered for a reflash, just link them out again when my new system is up. I still have to reinstall all IPKs, which is a bit time consuming, but it usually helps me to keep my system clean (not installing useless packages again ). This way I got my 30min/reflash time too.
Zumi
Ps.: For those who are wondering where have I gone from the forum/development: I got quite a hard semester at the university, and have to do more things anyway than I usually do, so -- sadly -- I don't have time now. So no new fvwm-pdaxrom releases or gpsdrive ipks in the near future.