As I read the instructions on the Remastersys web site the CD/DVD it
creates is similar to an Ubuntu Live CD except that it contains the
programs etc you've installed as well as your personal data. If that
will fit onto a DVD then you should be able to boot with that and
install *your* Ubuntu onto a new HD.

Interesting idea but you do need to do nothing at all with the PC
whilst this backup ISO is being created, plus any proprietary video
drivers won't port over and will need to be re-installed.

If you don't want to re-install then perhaps AptonCD would be a better tool.
It is not for running a Live CD or installing, but rather just for having
the deb files on disk. It all depends on your purpose. One is for
re-creating an installation and the other just for getting the apt files
onto disk.

I think I have it figured out! according to the listed limitations of
remastersys any restricted applications may make a useless disk, a
limitation of casper. I will just have to install such drivers after
the install to save people from having trouble installing using the disk.

The other desired apts will have to be on a separate disk using
aptoncd. I understand this limitation and will have to live with it.

They suggest testing the disk to make sure it is good but they didn't
suggest testing by install and that was my problem. On my machine my
old install has been save and will run from USB but history will have to
stay history as any further work will be limited to loose as you go. No
more saving my work.