matt79, thanks for the Last Session. First you are running nLite under Vista (or W7) to create an ISO for XP. This will not work when a Service Pack is integrated, which you have done. I have never seen the Application Data name for the I386 folder before and assume it has nothing to do with using Vista. It is best to use XP to run nLite. You can do this under VPC, if you don't have an XP system to use. Please go to Google and paste 'nlite "recovery partition " site:http://www.msfn.org', without the single quotes into the input line. You will get many good hits and hopefully some real help. Enjoy, John. I am using W7 pro. I know it says I integrated a service pack, but I did not. I will try to do the I386 with nLight in an XP pro virtual box machine and see if it comes back better. Thanks, Matt