30 April 2013

Creating boot USB stick with Windows 7 download tool fails on brand new USB drive

Loads of new USB flash drives come "prepared" with all manner of stuff on it.  If like me, you often just want to use the USB drive as OS build device you need to have it in a "native state" before you can use the Windows 7 USB/DVD download tool

http://images2.store.microsoft.com/prod/clustera/framework/w7udt/1.0/en-us/Windows7-USB-DVD-tool.exe

You will know that your USB drives needs to be when you receive the following error message

"We were unable to copy your files. Please check your USB device and the selected ISO file and try again."



DiskPart
You can resolve the issue using diskpart with the following list of commands

diskpart
list disk
select disk 1
clean
create partition primary
select partition 1
active
format quick fs=fat32
assign
exit

This assumed that the USB drive was identified as disk 1

PowerShell
Alternatively you can also use PowerShell in Windows 8 or Server 2012


Get-Disk 
Initialize-Disk -Number 1 -PartitionStyle MBR
Clear-Disk -Number 1 -RemoveData -RemoveOEM
New-Partition -DiskNumber 1 -UseMaximumSize -IsActive -MbrType FAT32 
Get-Partition -DiskNumber 1
Get-Volume
Format-Volume -DriveLetter f -FileSystem FAT32


This assumed that the USB drive was identified as disk 1 and that the partition was assigned drive letter f

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