If you have a working PirateBox on a flash card, you can use another linux computer and the "dd" command to make an exact copy of the working flash card onto a new flash card using the "dd" command. For example:
Now, you have an exact duplicate of your original PirateBox flash card (sdX) on your new flash card (sdY). So, X and Y will be a,b,c, etc., depending on what your Linux computer names them when you plug them into it. If you accidentally get them reversed, you will erase your working PirateBox flash card.