OK, so I should just set-up a local instance of TKL Core and rsync with fingers crossed? 

One concern is that there have been some server tweaks done on both installs but especially the django app so I'd like to just pick up the whole system and plunk it down if I could.

I guess I've just recommended another product for you guys...

I know VMWare has a client that does that, it's called the configurator or something like that.