I d start by having a look at the output of the buildroot tool which comes with busybox.
You are suggesting that you want to make your own Linux distribution, this is fine but you really need to know how to use an existing one first. I am assuming you understand fully how Linux boots and works on a basic level. You ll need
- Some kind of boot media (in some cases this CAN be a rom, but usually isn t) that the firmware can boot from (in most cases the firmware on x86 is some kind of bios, or bios-like - except on things like Macs)
- A boot loader - I like to use syslinux because it s easy (and boots from a dos filesystem)
- A kernel
- A root filesystem of some kind - you can use an initramfs for this in which case, it s loaded by the bootloader and expanded at boot time. Initramfs is cool, it avoids the need for a "real" root fs or block device drivers etc (at the expense of some ram, but ram is easy).
- A C library (unless all your exes are static linked)
- Some userspace software
I d strongly recommend using an emulator (such as vmware) to test this, it reduces turnaround time a lot. A development system will need to have rather a lot of disc space, as you ll probably need to compile everything in the above list, and possibly some other tools as well (such as gcc and C library) which aren t small. Your build box will probably need to be running a proper Linux distribution.
I have done this and it s good fun, but frustrating at times (debugging can be a mission in itself)
Happy hacking :)