> I'm thinking of something along the lines of a simple tarball of a few 
> essentials (i.e. stage3 + kernel + network settings) and then simply 
> getting the remainder pre-compiled binary packages off an ftp server 
> somewhere in our network as we want to keep this down to 1 cd.
> However, I've never had to do anything like this before - so I'm at a 
> bit of a loss.

Sounds good.
You install Gentoo on some machine, tar the whole filesystem (without
including mounted /proc, /sys, /dev ones), then you untar on the target
machine, install bootloader, and that's all.
I see no problem. You think good. You just do it. :-)

Of course, if machines hardware differ, you should consider kernel
issues, maybe CFLAGS differences... However, these are details.

> In short, are there any better ways of doing this (instead oftarballing 
> the the whole thing and throwing it onto a livecd)?

Maybe, but the first is OK.

> Where can I 'trim the fat'? (i.e., /usr/portage and the ilk)

Network filesystem mounted with readonly permission?

> Also, are there any tools for mass remote administration? SSH is nice 
> and all, but it would be awesome if one could tell 30 machines to 
> shutdown -h now simultaneously.

See x11-terms/pssh in portage (http://www.theether.org/pssh/).
or: 
for host in $(cat ./ips); do ssh $host command; done
 

> I'm perfectly content with editing a knoppix iso (gentoo live cd's have 
> a tendency towards not booting on our Dell Optiplex GX1's  ( 
> http://support.jp.dell.com/docs/systems/ban_gx1/specs.htm ), which are 
> the bulk of our lab), deleting all of the unecessary stuff and adding 
> the tarball in some random folder - but it feels so... unelegant.

If it works...
Many years ago I read about a nice solution of a 'computer
related problem'. Company A had to transmit some data to the other part
of a city. While there were a lot of possibilities, the best solution
turned out to use.. pigeons! Was that 'elegant' solution? ;-)

That book was 'Programming pearls' if I recall (and translate) correctly.
Wonderful reading...

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