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I have the same issue, I use 4GB USB drive to make bootable installation. my log file has 2009/02/14 20:17:18- WinSetupFromUSB 0.1.1 started 2009/02/14 20:17:18- OS WIN_XP X86 ServicePack: Service Pack 3 2009/02/14 20:17:18- Getting USB drives information 2009/02/14 20:17:18- Found USB Physical Disk: Lexar JD FireFly USB Device -- \\.\PHYSICALDRIVE1 2009/02/14 20:17:18- Found USB Disk Partition: Disk #1, Partition #0 2009/02/14 20:17:18- Found USB Logical Disk: E: File system: FAT Bootable: -1 2009/02/14 20:17:18- Target drive selected- E: 2009/02/14 20:17:18- Drive letter of the active partition in selected disk- E: 2009/02/14 20:17:18- Total target size avialable- 3824 MB 2009/02/14 20:17:18- Checking sizes... 2009/02/14 20:17:18- Total source size- 0 MB 2009/02/14 20:17:18- Target space available- 3824 MB 2009/02/14 20:17:22- Checking sizes... 2009/02/14 20:17:22- Total source size- 554.4 MB 2009/02/14 20:17:22- Target space available- 3824 MB 2009/02/14 20:17:22- Windows source selected- D: 2009/02/14 20:17:22- Source version- Windows XP Professional 2009/02/14 20:17:22- Service Pack- Windows XP Professional Service Pack 2 2009/02/14 20:17:22- AMD64 flag- 0 2009/02/14 20:17:24- Removing TEMP folder 2009/02/14 20:17:24- Backing up MBR of disk #1 2009/02/14 20:17:24- C:\Temp\Install XP from USB\WinSetupFromUSB\files\grub4dos\grubinst.exe -s=mbrdisk1-20090214-201724.dat -t (hd1) 2009/02/14 20:17:28- grubinst.exe could not make a backup of MBR of disk #1 2009/02/14 20:17:28- ---------------------------------Program quited----------------------------------------------- I got a "grubinst.exe could not make a backup of MBR" error when I try to launch the process. My 4GB USB stick is already formatted to FAT32 (I also tried NTFS) with HP utility. Any hints? Thanks Hardy