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Bootable USB fails with build #6151

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Build #6151 broke the bootable USB stick creation, the resulting stick boots but does not work.

Using the original Dutch ATIH 2012 build #5545 with Plus Pack I created a rescue image on a 256 MB Sandisk drive. The PC boots fine from the stick and ATIH 2012 works fine.

Yesterday I updated to build #6151 (also Dutch) with Plus Pack (same build) and recreated the rescue image on the same USB drive (which is then formatted first). The PC boots fine and I get the menu. When I start ATIH 2012 from the menu an error occurs, the program cannot be started, claims it cannot find the ramdisk. So it just doesn't work. Tried a few times but keeps failing.

I also created a bootable CD, which seems to work - that is it starts the program correctly - have not actually used it.

I restored the image with the #5545 build (was a bit of a struggle without a working USB stick and the ATIH 2010 version does not accept the 2012 image). After restoring I recreated the rescue image on the same USB stick. The stick now works again, build #6151 broke this function.

By the way: Why does ATIH 2012 need a 256 MB sick while ATIH 2010 fitted on a 128 just fine with 45 MB left over! It went from 80 MB to 200+ MB, it's insane!

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It works when writing to a 512 MB SD card and a 4 GB USB stick. I guess a 256 MB USB stick is not big enough any more, although everything seems to fit on the disk. I retried creating the disk without Acronis System Report, then the 256 MB USB stick works too in that case.

Update:
Found the problem! Without Acronis System Report there are MORE files on the USB stick compared to with ASR. The image does NOT fit on the 256 MB stick after all and parts are missing. The only problem is that the boot disk builder doesn't issue an error when the USB stick runs out of space and just says okay...

I also run Acronis Recovery "Disk" from a bootable USB flash drive. I used Xboot to create the bootable USB flash drive, and loaded the Acronis Recovery bootable media ISO, build #6154. That ISO file alone is 277 MB, so clearly it would not fit on a 256 MB flash drive, even before consideration of the room needed for the Xboot files.

Flash drives are so cheap now, there's no reason to fret over trying to fit ATI onto too small a drive. Currently my Xboot is on a 1 GB flash drive containing the Acronis Recovery bootable media ISO, Partition Wizard ISO, and Windows 64-bit Recovery IS and I still have almost 500 MB free to add other ISOs.

Sure, USB sticks are cheap. The thing is, I have these old sticks laying around and they are ideal for use as bootstick since they are hardly usable for any other purpose any more. So I have a 128 MB Sandisk Cruizer stick I use for Acronis True Image Home 2010. Now with 2012 I wanted to use another 256 MB Sandisk Cruizer stick also collecting dust otherwise. It may be a moot point, but there is no excuse for bloating software. How come the program became twice as big as before, it for sure did not add that much features. Anyway, it fits without the Acronis System Report program which I was not intending to use anyway so no problem now.