If this has been written and I could not find it please forgive me for I could not find it

I wrote this because I couldnt find a generic tutorial anywhere on the net.

For the following guide you will need the following
• Original Windows XP-sp2 CD ( I used windows Xp install disc with Service pack 2... i believe service pack 1 will work as well)
• USB hard drive or USB-Flash (any size from 256k up to 2G)
• Barts PE Builder
• PeToUSB utility

Note: Barts PE Builder has an install utility that will install and allow you to create shortcuts on desktop

The PeToUSB utility is in a zip format - you need to extract the files and run the PeToUSB application directly from the directory you unzipped them to.






1 Insert your windows XP-sp2 CD (if the auto-run feature pops up just close it )

2 Run the PE Builder program you downloaded earlier
The program will search your PC for your windows CD or windows installation files

A. Ensure that •Create ISO image: is selected
(the default name will show up as pebuilder.iso and I am leaving it like that for this tutorial)

B. Click on [Build] (the first time you do this it will need your permission to create the output directory)

C. Read and understand the Windows License agreement that pops up
and then click [I agree]

The PE Builder will then build its file structure for you.

This will take some time based on your hardware it will be different for everyone.
in my case it took approx. 2 minutes to finish.

3. Insert your USB flash drive or key into an available USB port

4. Run the PE2USB program you downloaded earlier

A. In the ---Destination drive area--- check to make sure the correct usb device you want to write to is selected.

B. In the ---Format Options--- area :
Put a check mark in Enable Disk Format
Put a check mark in Enable LBA (FAT 16X)
Type a Name in the Drive Label Section

C. Click [Start]
D. A popup window will appear and then Click [Yes]
F. Another popup window will confirming you are erasing your USB drive Click [Yes]

This will take some time based on your hardware it will be different for everyone.
in my case it took approx. 3 minutes to finish.

G. Another popup window will appear saying completed successfully! [Click [Ok]

H. PeToUSB should still be open... In the ---Destination drive area--- check to make sure the correct usb device you want to write to is still selected.


I. click on {Tools} then Click on {Display Drive Info...}
Look at the partition table midway down the popup window and check partition 1 it should read something like :

Partition Table
No Boot Type StartCHS etc.
1 0x80 etc.
2 0x00 etc.
3 0x00 etc.
4 0x00 etc.

we just need to look at the first one it should read 0x80 below the Boot column if it says 0x80 then it should boot correctly.

5. once it is complete close PeToUSB and try booting the Flash Drive on your PC or Laptop (assuming your bios is already setup to allow you to boot from USB)

Thats it if all worked well you should be done

there is no reason to read below if it worked


I used the above guide on a computer running Windows XP - if you are running Windows Vista or windows7 you may run into issues because of the read/write permissions.


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Alternate Method

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I ran into a problem on one of my USB Flash Drives in this case it was a PNY Attache' 2G USB flash drive.

what I found is that no matter how many times I tried the Original method.. I kept seeing 0X00 on partition 1, Meaning the Master Boot Record (MBR) did not have itself flagged as a bootable partition

Now I am sure there is an easier way to do the following but until someone tells me otherwise....... here is the way I skinned this cat.


For the following guide you will need the following
• Original Windows XP-sp2 CD ( I used windows Xp install disc with Service pack 2... i believe service pack 1 will work as well)
• Windows 98CD or some form of bootable DOS
• USB hard drive or USB-Flash (any size from 256k up to 2G)
• Barts PE Builder
• PeToUSB utility
• HP's USB Disk Storage Format Tool
• Windows 98 or some form of bootable DOS





1. Download and install the HP USB Disk Storage Format Tool on the HP website look for SP27608.exe or just google it.

2. Provide or donwload some type of DOS operating system ( search for "windows98 system Files")
In my case I had some old windows 98 bootable discs and used them. you can probably use Freedos or find a friend with a disc.

3. Insert your USB Drive into an available usb port

4. Start the HPUSBFW.EXE program ( the default path should be C:\DRIVEKEY\HPUSBFW.EXE )
A. Here you need to make sure the Device section is populated with the drive you want to format
B. In the File System Section we want to select FAT
C. In the Volume Label you can put a name for the USB Flash Drive
D. Put a check in the Box That says [Create a DOS Startup Disk]
from the •Using DOS System Files Located At... click the button that allows you to browse your Computer and locate the Window 98 SYSTEM files or whatever OS you are going to install.

5. Click [Start]... A Popup window will inform you that you are going to format your USB Drive..Click [YES] to continue
when it is done a popup window will inform you of the new info on the drive click [OK] and close the HP USB Format tool


6. Insert your windows XP-sp2 CD (if the auto-run feature pops up just close it )

7. Run the PE Builder program you downloaded earlier
The program will search your PC for your windows CD or windows installation files

A. Ensure that •Create ISO image: is selected
(the default name will show up as pebuilder.iso and I am leaving it like that for this tutorial)

B. Click on [Build] (the first time you do this it will need your permission to create the output directory)

C. Read and understand the Windows License agreement that pops up
and then click [I agree]

The PE Builder will then build its file structure for you.

This will take some time based on your hardware it will be different for everyone.
in my case it took approx. 2 minutes to finish.

8. Insert your USB flash drive or key into an available USB port

9. Run the PE2USB program you downloaded earlier

A. In the ---Destination drive area--- check to make sure the correct usb device you want to write to is selected.

B. In the ---Format Options--- area :
Put a check mark in Enable Disk Format
Put a check mark in Enable LBA (FAT 16X)
Type a Name in the Drive Label Section

C. Click [Start]
D. A popup window will appear and then Click [Yes]
F. Another popup window will confirming you are erasing your USB drive Click [Yes]

This will take some time based on your hardware it will be different for everyone.
in my case it took approx. 3 minutes to finish.

G. Another popup window will appear saying completed successfully! [Click [Ok]

H. PeToUSB should still be open... In the ---Destination drive area--- check to make sure the correct usb device you want to write to is still selected.


I. click on {Tools} then Click on {Display Drive Info...}
Look at the partition table midway down the popup window and check partition 1 it should read something like :

Partition Table
No Boot Type StartCHS etc.
1 0x80 etc.
2 0x00 etc.
3 0x00 etc.
4 0x00 etc.


I hope this guide helps someone













Windows XP-sp2 ( I used windows Xp install disc with Service pack 2... i believe service pack 1 will work as well)
USB hard drive or USB-Flash Memory
Barts PE Builder
PeToUSB utility

Barts PE Builder has an install utility that will install and allow you to create shortcuts on desktop
PeToUSB utility is in a zip format - you need to extract the files and run the PeToUSB application directly from the directory you unzipped them to.

I used the above guide on a computer running Windows XP - if you are running Windows Vista or windows7 you may run into issues because of the read/write permissions.





I am pretty sure the flame posts will begin.. as I said I tried to create an easy to follow guide that I could not find anywhere.. and again sorry if its useless info

Nice tutorial, Goofy!

Thanks, I'm sure some members will find this very useful!!!

I took a crack at it about 2 years ago, lost in the forums, here:

http://www.911cd.net/forums//index.php?s=&...st&p=128540

and here:

http://ubcd4win.com/forum/index.php?s=&...ost&p=43811

Love these little USB sticks!

Picked up 2 SanDisk Cruzers, 16 GB each, at Costco last night, with a $7 coupon off of each one:
about 32 bucks apiece.

Put "full-bore" XP Pro Media Center Edition on one last night - works like a bomb,
taking up about 1.8 GB. But, must boot thru C:\boot.ini

USB HDDs are about the same process, just have a 2 GB partition for BartPE,
the rest can go FAT32 or NTFS, for whatever....

There's a USB HDD blurb here:
http://www.911cd.net/forums//index.php?s=&...st&p=128238

Goofy, this is a very nice tutorial. It could have saved me time in the past, but I did learn from all the reading and testing.

I have had initial success and failures getting a jump drive bootable as well. I have refined my process for handling initial failures with another feature of PeToUSB. Another of the 'Tools' available is the 'Backup MBR...' and 'Restore MBR...' I have backed up the MBR of a successfully bootable USB drive into the PeToUSB folder. When I build a USB drive that fails to boot, I restore the saved MBR onto the USB drive and rebuild the drive. It has not failed for me, hopefully it will be as successful for others.

I actually did it this way myself but didnt write it in to tutorial for a couple goofy reasons.. 1.. I assumed they did not have a bootable usb device to grab an mbr. and 2.. I was not to sure if I used mbr's from different sized devices would it screw up the file structure in the long run.. probably not but I wasnt sure..

thanks for appreciating the tutorial though.. I do hope it becomes usefull to someone someday..