After painfully giving up, I have 3 Flash drive sticks which have all worked flawless.. I recently purchased a Kingston Data Traveler DTI/4GB STick. I have formatted a USB with a Bootable configuration using just DOS based image. This works flawless in every Flash stick but the Kingston.. The kingston shows an ACTIVE PARTITION, all the necessary boot files and Remains the only device that will not LOAD its Boot partition when selected from the BIOS of a Computer. The technique employed is : Format with HP utility for USB flash memory devices. ---set for Quick format ( as I have done a full already ) --- Included the Simple win98 operating system as a base file system ( io.sys,msdos.sys,command.com) That will make a Usable DOS START DISK with any of my USB Keys( flash memory ) except for this 4GB kingston stick.. I have to also note, vista OS did not like or recognize the device properly as a usb drive, it kept failing to install it, and I had to load a Device driver for it.. What a pain that was.. PNP BIOS Vendor information problem.. which is resolved.. So any experienced people care to enlighten the possibilities of why it wont boot ? * could it be a Cluster size conflict with the USB ELtorito standard ? is that a Bios vendor issue ? Thank you for your input