I managed to make bootable USB stick from XP SP3 ENG. During file copy(after HDD format), i will get 'Setup cannot copy the file:XXXXXX'. XXXXXX, will be random. For example win32spl.dll, inetpp.dll and etc. My USB stick is formatted to NTFS. I have tried FAT32 and using 16GB SDHC too. I don't think my card is faulty though. I have tried to use different memory card reader too.