Rebuilding Orsino - USB
I've never really tried getting USB to work on Linux before - I just assumed that it would be too difficult. Turns out that that's not really the case after all - although we're not talking plug and play here.
Key documents are HOWTO USB Mass Storage Device and HOWTO Submount.
Since I'm running a 2.6 genkernel it already handled hotplugging and a USB flash device plugged in appeared in /dev/sda1 and I could mount it manually. The first document above shows how to hardwire a particular device type to a device node (ie our LEXAR USB stick now always appears as /dev/usbstick), the second how to setup submount to do auto mounting and unmounting (there seem to be numerous ways of doing this in Linux - but this one, so far, appears to work very simply).
So I created /mnt/usbstick, added the local udev rule, added the entry to fstab, added subfs to the autoload modules, poked a few bits and now I can insert and remove the stick and have it appear at /mnt/usbstick automatically.
Super.

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