Currently mkbootdisk can not make boot image as a file. It would be nice if mkbootdisk --device file.img 2.4.18-5 would save image to file. (in a similar way as syslinux does) The required changes in mkbootdisk are very simple. For example this "quick hack" allows saving a boot image to a file. 1. take any existing image, like boot.img and copy it to file.img 2. edit mkbootdisk and replace in /sbin/mkbootdisk mount -t vfat $device $MOUNTDIR by mount -o loop -t vfat $device $MOUNTDIR After this "quick hack" (which only demostrates the simplicity of the new functionality implementation) mkbootdisk writes a boot image to file.img So all the infrastructure is already there, only few little changes in option parsing are required to make it working in a nice clean way.
If you use a non-existent file at least as of 1.5.0, this will work and create the file for you.