Thanks to everybody for feedback!
So things look good and I'll roughly proceed as sketched out.

One clarification: I like to have individual /home/user/ directories so apps from different distros can put their conf files and directories underneath, without colliding with each other. My personal data and scripts get mounted some place else, and symlinks like
  $HOME/bin/  => /mnt/hdaX/bin/
in each distro then yield the same environment.
If I get tired of this approach I'll just replace the symlinks with real directories and copy the real files into them. Then I just look like everybody else. I'll even put some basic stuff in /mnt/hdaX/bin/ before I mount /dev/hdaX/ over it so if the mount fails I am not left with dangling links. At least that's the plan. Maybe a follow-up question: are the files (inodes) mounted over protected against write? (in the past I never had a problem with it, but that could have been just luck?)

Re Knoppix remastering: Yes the author of Knoppix Hacks creates a 1 GB swap file on top of 512 MB RAM. But you can't reuse the content of it. The modified and uncompressed distro, as well as the final .iso are build on the HD. So you can boot into various ISOs using cheatcode bootfrom.

 - Horst (now I'm really off for the day :-)

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