Thanks for the suggestions.  The small usb idea, was just for me, not something I was advocating for all armory users to mess with.  Don't get me wrong, I really like Armory.  After spending a long time looking at alternatives, I decided Armory is the closest alternative to a perfect solution that is out there.  Most of the paper wallet solutions available, really are not truly "offline" solutions to me when the private keys have to, eventually, enter something that runs online where, practically speaking, the environment cannot be guaranteed to always be 100% secure.  Only using the paper wallets to send once & then sending the change to a new one, was one idea, but that seemed like it would get confusing to me after doing it for a while.  Armory is the only easy-to-use solution I could find, that doesn't have you trusting an online environment, or relying on a web page that might not be there someday, to transmit the signed transaction.

Having thought about the weakest point though, I would like armory a little better if it printed OCR codes to return the signed transaction to the online wallet to transmit.

For a USB, I'm happy trying a solution that will work for *most* transactions I might make, maybe enlarging the partition or moving to new keys with no transaction history, as my previous transactions eventually grow too long.  I will give it a try.