The initial bit with directly modifying the variables.dat and BS.ini files was probably too much...I was pretty much grasping as whatever I could :) (though, I later found out that the editable version of variables.dat which I was working with, was
not the actual dat file created when the wizard first started...that file was located somewhere like x:\smsdata\...\... and was all encrypted...so no editing happening there).
Our naming convention is broken down first by a 3 digit code for building location, and then followed by either a room number or username (in some buildings), and then a two digit number to specify which workstation it is in the event of multiple workstations
per room. This makes a ZTI for barebones imaging difficult.
What I have running now is this...firstly I modified the wizard.hta file to include a password verification in order to prevent any unauthorized access (since we have PXE password protection disabled...that way we can still have remote PXE imaging without
needing to enter a password for a required TS). I also used the IsComputerKnown webservice call to check and see if the computer has a DDR. The problem I was running into with using the custom boot wizard for unknown computers, is that even though
the computer was getting created in sccm and added to a collection, in the end there was also another DDR getting created for the same computer using the MAC address (I suspect this is similar to how a computer will be listed in the direct membership of an
OSD collection, but not actually show up for a few minutes).
This being the case, I too have a single TS for image deployments...I then deployed the TS to unknown computers and if the IsComputerKnown check returned false, then after entering the password in the wizard, it would cancel the hta and proceed onto the
TS for unknown computers (where I have the OSDComputerName variable waiting to be set). This correctly images the workstation and adds the appropriate DDR to SCCM.
As a side note, imaging for known computers has never been an issue and still continues to work without any issue.