correct me if im wrong but FAT32 cant handle s file bigger than 4GB, how big is the install.wim? You can use vlite, which will make it less thn 4gb if you remove the uneeded drivers, languages, etc... but will only have one version of vista on the usb stick... or you can look on google to see how to exeed the 4gb limit. What i did was remove all un-needed lanauges, drivers, etc.. an then rebuild, and did the same for each vista version eventaully had a rebuilt image of each vista version and then in the end just merged them back together and the overall install.wim size was smaller. So its like using the apply method on all of them but my way makes the install.wim smaller, if that makes sense