Easiest/best way to "copy" a robot

I wouldn't do an image to duplicate between lines, I believe images take mastering data so you'll make more work for yourself. I haven't tried an AOA from one robot to another, I've always been too weary about getting a couple files that could be a problem. I would take an AOA and take all of your TP and karel. I think these will get you most of what you need: diocfgsv.io, numreg.vr, posreg.vr sysegd.sv, sysframe.sv. There may be a few more, but these will get you most of the way there.

Don't forget to copy over the payload data.

I think that means the robot you are loading the files to is a different software version.