I am fairly new to Linux but after looking around i have found Porteus to be the best for my needs however i could really use some help

i am using Porteus-KDE-v2.1-i486 i built it with developer tools and libre office Firefox the whole shebang if you would.
OK so here is the problem in always fresh mode it runs perfect starts fast opens everything etc no problems yet even when i put a save module not .dat file but the save changes module it dose fine.
but when i put a save file in fat 32 a save.dat file ( I have tried all three possible file extensions with and without encryption ) and i link it in pouteus.cfg like the directions say in install portheus it starts i put my password in or not it loads my file ect but then it starts to consume my Intel possessor dual core 100% well after about 25 30 extra seconds it finally slows down usage but try to open Firefox and again 100% both cores sometimes it starts sometimes nothing and when it starts it freezes, and when it doses nothing it says its and iI try again it says its already running.
and same thing when installed to ext 2,3,4

ohh and installing from windows has given me best results
tried all on usb 8gb kingston and pny
what i would like is one of 2 things
#1
[1gb fat 32 virtual box]locked [and remaining 6.7 ext ? for porteus ] password protected
I travel alot security is a must
or
#2
[1gb fat 32 virtual box] locked {remainder fat 32 porteus with 2gb expandable file]
but I will take what i can get as long as it KDE and super hidden on my usb with options of virtual box.
thanks for any and all help
