I have done some experiments and succeeding in preparing an OSGeo4W install CD that can be used instead of installing from the network.
I had to fix some problems with "local mode" in the express install logic. I also added logic so that "-L -l _cwd_" can be passed on the osgeo4w-setup.exe commandline to run in local mode using the current working directory as the package cache. With those changes (uploaded already) I was successful making a CD. I also created an autorun file:
A similar approach can be used to create a auto-running USB key, though it requires small changes to the autorun.inf file.
The CD image is essentially a clone of:
and all the subdirectories. There are various means to get this tree, but I used the rsync command:
rsync -av download.osgeo.org::download/osgeo4w .
It would also be interesting to have an *installed* OSGeo4W tree on a CD. I have not tried this yet.