I've also had problems. I saw nLite described in the latest Custom PC mag, and as I'm in the process of reinstalling my work PC, I thought it sounded useful. Optimistically, I decided to: - start with my MS original "Gold" XP SP1a disk, (OEM variety) - slipstream SP2 - add a pair of new disk drivers - integrate a bunch of hotfixes (about 12) relating to IE and Core XP - disable a couple of programs: windows messenger, novell networks - do a few tweaks to the registry and general setup. Things seemed ok, other than not at first realizing that the iso file had merely been created, not written to disk! However, the first time I tried installing, I left the PC to it for a while, and when I came back there was a message asking for the SP2 Disk for the file "asms". Ther's a directory asms there in the SP2 extract directory, but at that point I had no way of making it available and setup refused to carry on without it. Following this, I found that the new setup disk would boot as far as disk formatting, etc, but although the new hard drive partition "booted", it didn't start properly - it fails very quickly with a long message about invalid paths and directory contents. I checked the original driver.cab and the driver.cab that nLite generated, and the generated one has about 4444 files in it, while the original has 4657 files. The missing files seemed fairly basic: stuff like IP connections, atapi drivers etc. Might it help to do the slipstream "manually"? Ruth P.S. My runs of expand.exe both went without a hitch; no bad files, no issues.