I now have a working procedure ... with some odd things still to be explained ... but it's better then nothing.
Same link as before (my home page, zaurus on the left, documents on the top, r121_system_backup.txt) ... make sure you hit refresh if you had a look at it previously.
BTW: has any one any explanation for the disk usage difference ?
if any one else wants to try ... tell me if you also have slightly different disk usage after the restore (via PM).