Is it really possible to make your own distro at home?
Indeed. Check out http://www.linuxfromscratch.org/ for details.
You might want to go through the following article before you proceed: http://www.osnews.com/story.php?news_id=3431
I believe, a few PLUGgies did develop a Linux distribution of their own sometime last year. It was called "antomics". The announcement can be found in PLUG Archives at http://plug.org.in/pipermail/plug-mail/2002-September/005427.html for further information.
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