GOAL: A master PiBot image that is pre-configured for ease of setup.  The image should be as small as possible for storage and distribution.  The image should be easily installed onto an 8GB or larger uSD card.

EQUIPMENT USED:

    Windows 10 PC with SD card reader
    Sandisk microSDHC UHS-I Card 8GB (any class 10 8GB card should do)
    Win32 Disk Imager (https://sourceforge.net/projects/win32diskimager/)
    SD Formatter (https://www.sdcard.org/downloads/formatter_4/)
    Cygwin with dd and openssh packages installed (https://www.cygwin.com/) (I use the 64-bit version)
    Raspbian Jessie with Pixel OS (https://www.raspberrypi.org/downloads/raspbian/)
    Apple Bonjour print services for windows (https://support.apple.com/downloads/bonjour_for_windows)

PROCEDURE:

    Install PC software (sd formatter, disk imager, cygwin, bonjour)
    Prepare SD card:
        Install Raspbian on SD card (see: https://www.raspberrypi.org/documentation/installation/installing-images/README.md).  This creates two partitions: /boot that is accessible from Windows and /root that is ext4 and cannot (easily) be accessed from Windows.
        Edit /boot/config.txt
            uncomment framebuffer_width=1280
            uncomment framebuffer_height=720
            uncomment dtparam=i2c_arm=on
            add at end:
            gpu_mem=32
        Edit /boot/cmdline.txt
            Insert after rootwait:
            modules-load=dwc2,g_ether g_ether.dev_addr=5a:77:1e:af:8e:9e g_ether.host_addr=72:8d:1f:c4:e8:ca
            Remove init=resizefs...   (to prevent automatic expansion to full SD card size)
            (Note: cmdline.txt must be a single line...no linebreaks)
        Create an empty file: /boot/ssh   (enables ssh server when started)
        Optional: create /boot/wpa_supplicant.conf with your wifi network configuration information (allows Pi to connect to your network on boot)
    Boot and configure SD card in Pi
        Place uSD card in Pi Zero
        Connect USB cable to Pi Zero OTG port
        When it finishes booting (LED stops blinking) ssh to pibot.local using putty or cygwin ssh or ...
        login as user 'pi' with password 'raspberry'
        sudo raspi-config
            Setup localisation settings for US, English, EST
            Setup interfacing options: enable ssh, vnc, i2c
            Setup Advanced options: hostname->pibot
            Resize /root partition to 5GB.  See: http://elinux.org/RPi_Resize_Flash_Partitions
        Get a network connection for the Pi using one of the following methods:
            Bridge your main connection on the windows 10 machine (Ethernet or WiFi) to the NDIS Ethernet connection for the PiBot USB OTG network (select both connections in the Network Connections then right-click and choose Bridge Connections); configure the DNS server as 8.8.8.8
            Connect a USB Ethernet dongle to the Pi OTG connector
            Configure /etc/wpa_supplicant/wpa_supplicant.conf on the Pi to include your local WiFi network
        Update the OS on the Pi:
        sudo apt-get update
        sudo apt-get upgrade
        Install any needed packages
            sudo apt-get install subversion ant mercurial
            curl -s get.pi4j.com | sudo bash
        Install Oracle DIO (see https://www.raspberrypi.org/forums/viewtopic.php?f=81&t=99212)
            hg clone http://hg.openjdk.java.net/dio/dev
            export PI_TOOLS=/usr
            export JAVA_HOME=/usr/lib/jvm/jdk-8-oracle-arm32-vfp-hflt/
            cd dev
            make
            cd ..
            sudo mv ~/dev /opt/dio
            sudo chown -R root.root /opt/dio
            create /etc/ld.so.conf.d/libdio.conf  containing /opt/dio/build/so
            sudo ldconfig   (to refresh the library path cache)
        Do WiFi Configuration using hostapd and dnsmasq (see documentation)
        Once card is configured, shutdown Pi
    Make master image:
        Place uSD card in PC
        launch cygwin as adminstrator
        dd bs=512 ibs=1M count=10491904 if=/dev/sdb of=pibot_x.img
        (NOTE: 10491904 is one block past the last block of the /root partition on my setup - could be different in your setup depending on the amount of space you allocated when resizing the /root partition above.
        check the partitions in fdisk first.  On the Pi:
            sudo fdisk /dev/mmcblk0
            p (print partition table)
            note End block of /dev/mmcblk0p2
            Use that block number + 1 as the count