USB booting :: USB Partitions sda1 vs sda2 and free space

Here's the solution: Using a single, USB-ZIP bootable partition, install using the USB-ZIP method, but insall as an upgrade, so the script doesn't repartition.

Here's the solution on DSL: Install to the pen drive using the USB-HDD script. This gives a single, large partition, but uses a different boot method/sector... apparently :-/ Now do the USB-ZIP install as an upgrade, and you have a single, large vfat partition that boots using a BIOS USB-ZIP configuration.

Now, that wasn't so hard, was it? And I'm the DSL noob :-P

original here.