edit: success further down!
manual frugal of all files from the iso to folder in sda6 with grub code
title Quirky Xerus64 8.1.6 frugal in sda6
kernel /xerus64-8.1.6/vmlinuz rw pfix=fsck
searches through all drives then cant find /sbin/init and so kernel panics. ie doesnt boot.
same scenario as the last few 64 quirkys
last quirky that actually booted by this method was quirky64 8.0
my dvd writer was bjorked by pburn in fatdog710 so cant write to dvd and anyhow the last quirky i successfully wrote to DVD wouldnt boot either.
only have 2GB and 4 GB sdcards available which if BK would allow it would be absolutely fine for holding all the files by dd of compressed quirky files but he sees otherwise.
preferable would be to fix the manual iso extraction so that it actually boots from directory because if quirky is not on sda it will only be seldom used. no, not going to reorganize the sda HD for a new partition for each new quirky.
if dont want to make iso, jemmimah was able to just use a zip file which could then be extracted to directory and grub booted.
too much bending over backwards for windows and not catering for the existing audience and fellow linux users. windows dominance has long past </rant>