USB booting :: Problems with install larger than 128MB

I have a PQI Traveling Disk U250 512MB USB 2.0 pendrive that I am trying to install DSL on. I have managed to do so successfully and have it boot via 2 methods:

1) Do a USB-ZIP install creating a 50MB partition and a second partition that Windows can not access.

2) Do a USB-HDD install by first hacking the install script to have fdisk make a smaller (128MB) partition.

Unfortunately for me I'd like to be able to use the whole 512MB on a single parition. I tried using the Win-install method with no luck. I've tried using sfdisk to resize the CHS parameters on the device with no luck. Each method seems to install correctly but the machine always says it is not a bootable disk when I try to use it.

The original CHS parameters on device were C=1020 H=17 S=59. Using these values I hacked the USBHDD script to have fdisk use the first 255 cylinders only and could actually get the device to boot. I used sfisk to resize to C=255 H=68 S=59 and create a single large partition with no luck booting. Same thing when I tried C=255 H=63 S=63.

What could be preventing me from creating an install larger than 128MB?

Why won't Windows recognize more than one partition on a USB device. Say what you will about Windows good or bad, but come on! That's lame.

original here.