I suggest that Maurice uses a PCLOS Mini ISO, or any PCLOS ISO he may have on his HDD, and puts it on the USB stick using LiveUSB Creator.
If that does not work then we know it is not the ISO that is at fault, and can look for the possible cause.
If it does work then the personal remaster can be added to the USB stick ..... a known good & booting USB stick. If the personal remaster fails then we know that it is either the copying process or the ISO that is at fault which brings us right back to where we were much earlier in the thread.
As for the mylivecd process stalling ....... yes it takes a lot of time to compress the amount of data Maurice has in his remaster. Patience is needed
So, to Maurice ........ set up your USB device with at least one ext partition that is large enough to hold an ISO (1GB minimum, but much larger needed for larger or multiple installs).
Install, using LiveUSB Creator, some version of PCLOS on the USB device ....... using a known good PCLOS original ISO. Be sure to check the MD5sum of the ISO before using it.
Be sure you know and understand
the questions being asked while the script is running. If you don't, ask.
Also be certain you know whether you wish to do a new install or want to Add to an existing install.