I agree with Lanthanide. I realized that right from the start, but I didn't say anything because I assumed his true goal is to expand his knowledge and to prove a point. Dunno if you can impress your boss with such an ineffective "improvement".
Partially, it is, of course, the main reason why I asked on this forum was because I hoped that there would be a simple way to do what I was asking, obviously there is not.
Especially if by making this special disc image it ties you to using particular CD burning software - then if you want to make a replacement disc, you have to find the PC that has it installed, or install it on a new PC, which could be a problem if you can't find the software any more, or it isn't compatible any more, or x y z problem
With the method I would have had to go with, this actually wouldn't be a problem, because ISOBuster would simply allow me to ensure that certain files were given the larger LBAs, while the more important ones received the smaller ones. All of this would be saved inside the .ISO, meaning that any burning software would produce the same result.
If your new disc is going to replace an existing collection of 4-5 discs, then it is going to be far superior time savings anyway, so trying to edge even more out by making a disc in a special orientation is definitely what would be classed "diminishing returns"
It's actually a collection of seven discs, along with a vast collection of extra tools, so yes, it is already saving a huge amount of time, however, one to two hours of company time is worth spending if it means the difference between grabbing a unbootably corrupt disc before you leave for an on-site job two hours away, and grabbing one that simply has a broken driver pack.
Now, while I think with the information you guys have, it still makes sense to do so, the project plan has changed slightly, and I am now turning each of the programs I am adding to the built-in BartPE into plugins, so the programs available on the disc are entirely customizable, which means that each time a new configuration is desired, the entire process would have to be redone to make the disc less corruptible, a job I'd prefer to avoid.
I'd still be interested in any kind of software that makes a job like this easy though, because I can see it being useful, as long as it takes a reasonable amount of labor to perform.
None.