From Kb_JMY(晉明夷)

How to build a bootable USB finger?

Three items needed

• WinXP installation CD

-> or copy it into your harddisk, say, d:\WinXP_installCD

• BartPE:"pebuilder3110a.exe" -- Bart's Preinstalled Environment

-> download the latest version from nu2.nu

-> install it to, e.g. c:\uty_admin\pebuilder3110a

• PeToUSB.exe -- Application for formatting and making bootable, USB Flash Memory Drives

-> download the latest version from softpedia.com

Procedure

• Build the WinXP installation directory

1. execute "pebuilder.exe" -- you can find it from BartPE's installed directory, e.g. c:\uty_admin\pebuilder3110a
2. set WinXP source file directory: e.g. d:\WinXP_installCD
3. set custom folder or files need to been installed too, e.g. Acronis True Image boot CD <-- seems that nothing have been copied from there!
4. set output directory, e.g. c:\uty_admin\pebuilder3110a\BartPE
5. set media output to "none"
6. click "build" to start -- Note: it may take more than 30minutes to copy the files!

• Make the bootable USB finger

1. Format the USB finger using the Windows Explorer
2. execute "PeToUSB.exe"
3. set the source file directory to: e.g. c:\uty_admin\pebuilder3110a\BartPE
4. Format Options: check "Enable Disk Format" -- To make a USB Finger bootable requires it to be formatted to FAT16, the partition set as bootable AND the volume boot sector id to be set to 0x80. If all this is done the UFD should be bootable on any system whose BIOS can boot to USB-HDD. Some UFDs partition tables have been set to a starting offset of 32 sectors, this will not be bootable under USB-HDD. It seems that USB-ZIP requires this, USB-HDD requires offset of 63 sectors.
5. Check "Enable File Copy" & select "Overwrite Always"
6. click "start"
7. but...no luck, still cannot be bootable!