I used 256MB Flash Drive.
1.) Follow the installation instructions for UBCD4WIN you see here:
2.) Do the UBCD4WIN drivers and Plug-ins to your PEBuilder folder as you normally would. Due to size restraints you do NOT want to use the BTS Drivers, only the 1.7 standard version.
3.) Download and format your Pen or Flash Drive with this tool - here
The key here is to format your drive to FAT - this tool should auto detect your hardware USB Pen or Flash Drive (This is not for USB external Hard Drives).
4.) BartsPE Builder has the files needed to create the iso image for USB Pen and Flash drives in the root of Pebuilder (pe2usb.bin, pe2usb.cmd, pebuilder.txt) - The text file gives you directions on how to do this (READ it!!!) it has its own format option but for some reason if your device is not formatted to FAT it doesn't work when you use the pe2usb tool alone (This is why the HP formatter is needed ahead of time, at least in my experience).
5.) Create a folder in the root of Pebuilder called srsp1 and download this and extract to this folder (I've done all the hard work for you)... Get Here
6.) Now what I've done on mine was put Ghost 8.2, Firefox 1.5.0.1, 7Zip and other smaller programs (You have to toy with this).
7.) Build BartsPE or UBCD4WIN as you normally would disabling most of the plug-ins before hand (Remember Size Does Matter) - YOU DO NOT HAVE TO BUILD ISO - it creates the BartPE folder that is needed by pe2usb for building it's ISO on the Pen/Flash drive.
8.) Run this from a command prompt pe2usb -f <flash drive letter:> without brackets from the root of Pebuilder.
9.) Check for errors especially if you run out of space just keep working and only add what you really need and what fits.
I was able to have everything I needed on my 256MB drive and bootable and other than the ramdisk building (Depends on amount of RAM) this thing flies, much faster than using CD.
You can do as I did and have multiple folders with Pebuilder on your system - I use 3 different ones for building plug-ins, one for Pen/Flash Drive only and UBCD4WIN.
Well I hope I shed some light on this for those that couldn't get it to work properly I hope this helps and I hope I wasn't to vague but let me say it does away with the old CD and you also have to use ONLY on SYSTEMS that allow you to boot to USB Devices (This is found in BIOS). I've tested on Dell systems and servers - (Added my own Perc 4 drivers - servers only)...
So maybe with a bit of work the next step would be to create UBUSB4WIN - for multiple sized pen drives etc. omitting or adding tools to fill the different sized drives.. Don't all series someday have a spin off.
