Hi
I have been doing a lot of custom rtai kernel compiling, and recompiling emc etc recently, looking at latency reduction in the newer multicore computers.
(
www.linuxcnc.org/component/option,com_ku.../lang,english/#14321)
The kernel and magma kernel patch version I had most success with were 2.6.32
If you sort out the most recent Puppy Linux distro that will run on your machines, preferably with a 2.6.32-x kernel (or older - not newer the patches start running out ), I can have a look to see if I can install it and compile within it, to produce a compatible kernel - rtai - emc2 set for it.
My limiting factor will probably be the reverse of yours, I may need to get something out of the loft that is old enough to install Puppy Linux on!
A lot will depend upon just how many packages etc need installing to build emc in particular, all the python, tk, tcl, minigl etc etc
The puppy might be a St Bernard before I finish!
No promises, but I can give it a try, whilst I can remember everything required!
regards
PS Give me a link to CoolCNC05 distro too - so I can see exactly what that was - cheers