in this tutorial we will make a costom kali iso to write on any usb stick

dependencies:

apt-get update && apt-get install git live-build cdebootstrap

options

./build.sh --variant {gnome,kde,xfce,e17,lxde,i3wm,light}
./build.sh --arch {i386,amd64,armel*,armhf*}
./build.sh --distribution {moto,sana,kali-rolling}

example command:

./build.sh --distribution sana -variant kde -arch i386 --verbose

fist we will download the live build

git clone git://git.kali.org/live-build-config.git
cd live-build-config

edit (nano) kali-config/variant-light/package-lists/kali.list.chroot and add all the packages that you want. we will install apache for sake of example

cryptsetup
gparted
apache2
php5
php5-gd
php-db
php5-mysql

we will enable apache on boot

echo 'update-rc.d -f apache2 enable' >> kali-config/common/hooks/01-start-services.chroot
chmod +x kali-config/common/hooks/01-start-services.chroot

make the device bootable:

nano kali-config/common/hooks/02-unattended.binary and past the following
chmod +x kali-config/common/hooks/02-unattended.binary

to add an boot option:

#!/bin/sh
cat >>binary/isolinux/install.cfg <<END
label install
 menu lable ^Unattended Install
 menu default
 linux /install/vmlinuz
 initrd /install/initrd.gz
 appent vga 788 --quiet file=/chrom/install/pressed.cfg local=en_US keymap=us hostname=portable domain=portable.usb
END

costom wallpaper

mkdir -p kali-config/common/includes.chroot/usr/share/images/desktop-base
wget http://mysite.com/image.jpg -O kali-config/common/includes.chroot/usr/share/images/desktop-base/kali-wallpaper_1920x1080.png
wget http://mysite.com/image.jpg -O kali-config/common/includes.chroot/usr/share/images/desktop-base/kali-lockscreen_1920x1080.png

if you wanted to have an ssh key you can copy it there:

mkdir -p kali-config/common/includes.chroot/root/.ssh

if you wanted to have an unattended installer option

wget http://archive.kali.org/preseed.cfg -O kali-config/common/includes.installer/preseed.cfg

./build.sh --variant light --distribution sana --arch i386 --verbose