partition 1 named ext2 at least 500mb (fat32 file system)
partition 2 named swap at least 250mb (fat32 file system)
partition 3 named share the rest of the space (14gb in my case)
files in each partition:
in /ext2/ should have the 'piratebox' setup on it, including directors /bin/, /root/ /dev/ /etc/ and all the rest
in /swap/ there is nothing to start with.
in /share/ you create a dir called /piratebox/ which has the 5 files including favicon, logos, etc.
So, then you stick your USB into your Pogoplug or Dockstar and join the dd-wrt wifi and point your browser to . . . ?