> Do I also have to mount the rb disk in order to do the rebuild?

No.  Here is an example of a rebuild, done with only a DOS partition
to work with:

 cd /tmp               # on tomsrtbt, almost all the free space is in /tmp
 mkdir mnt1 mnt2                                     # make 2 mount points
 mount -t msdos /dev/hda1 mnt1          # mount the DOS hard drive on mnt1
 dd if=/dev/zero bs=1024 count=15000 of=mnt1/loopfile   # make a 15MB file
 mke2fs mnt1/loopfile              # make an ext2fs filesystem in the file
 mount -o loop mnt1/loopfile mnt2      # mount the loop filesystem on mnt2
 cd mnt2                              # change to the new filesystem drive
 unpack.s /dev/fd0u1722      # unpacking directly from the floppy diskette
 cd tomsrtbt-1.7.205.unpacked                    # cd to the new directory
 # make changes!                 # here is where you do whatever you want!
 2/usr/doc/buildit.s                       # now we build a new image file
 cd tomsrtbt-tomsrtbt-1.7.206          # the build goes in a new directory
 ./install.s                          # this command puts it onto a floppy
 umount mnt1 mnt2                                 # might as well clean up

Note, you do not need to do this if all you are changing is rc.custom.gz
or settings.s or if you have enough space on /dev/fd0u1722 to add stuff.

-Tom


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