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(sorry for the delayed response) Have you tried FAT32? I changed my script to format NTFS and now I can build a bootable USB key from WinXP. I would prefer to stick with FAT32 but will take what I can get. I also had to change the "Safe Removal Policy" ("Optimize for Performance") to allow the format to NTFS to occur. I know this is old, but the problem is that the XP version of Diskpart does not read USB sticks as "drives" unless the RMB (removable media bit) has not been set. Windows PE 2.0 must have the newer version of Diskpart. I am looking for a download of the Diskpart executable, or I can try to use a third-party program.