Hi,
I work off two USB's when on the road. First is created with grml2usb on
2011.05 and a GRMLCFG partition for persistence. Second is created with 
grml-crypto for for /home/someuser and /etc/vault. I was about to 
re-script what I do manually at boot when I discovered grub2 development 
tree now has a luks.mod (testing needed & i'm willing). I have built it 
from src and installed into grml-chroot on a squeeze host.  I expect to 
use grml-live per remastering instructions and then grml2usb.

GOAL;
  Phase 1 usb layout;
        1 Meg unencrypted boot/decrypt area
        remainder fat16 encrypted /boot. grml & grml64.
  Phase 2
        Unencrypted boot/decrypt area
        Remanider lvm2/luks encrypted (for single passphrase at boot)
                grml2usb partition with several flavors
                GRMLCFG partition
                home-rw
                live-rw
                home-sn (live-snapshots)
                live-sn.

I plan to contribute it back as either a --luks option on grml2usb or 
seporate script.

Have I missed any issues in reasearch you are aware of ?
Is this approach logical ?
Any pointers on how to proceede from chroot to usb ?
I'm open to any suggestions and could post bata of process as it would 
need to be tested on more hardware than I have available.

Thanks for your input,
Charles
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