I formatted a 16 GB USB Stick today so I could boot from it and that works great. The problem I have is it won't let me copy a 7GB Ghost image over to USB, it says there isn't enough space. When I look Windows shows there is 14GB available. Can anyone give me some insight into this issue?
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You probably have formatted the USB stick to FAT32 filesystem which does not support filesizes in excess of 4GB. Try reformatting it as NTFS.
Sathyajith Bhat
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While using NTFS instead of FAT32 may work, you can also get it to work with FAT32. You have to split the large image file (install.wim) into pieces of 4 GB. You can do it with the following command (where D: contains your mounted .ISO file and E: is your USB stick):
DISM /Split-Image /ImageFile:D:\sources\install.wim /SWMFile:E:\sources\install.swm /FileSize:4096
You can read more about the creation of a Windows boot stick in my answer here.
stackprotector
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You probably want to create 2 partitions, 1 small (FAT/32)to carry the boot records, and the other larger to store the ghost image.
– Sathyajith Bhat Jun 01 '10 at 22:05