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USB

Make That USB Drive DOS-Bootable

Eulogies

It's a fact that any storage device can be made bootable. We're used to systems booting from
hard disks, floppies, CD-ROMs and even DVDs, but it's only recently that the PC's BIOS has
supported booting to a USB device. So if the target system doesn't support USB booting then the
following won't work. Time to buy a new system. More on checking the BIOS later.
The easiest way to get the boot files for a bootable USB drive is to steal them from a bootable
floppy. So prepare a boot diskette to the desired specification. Note here we are referring to MS
DOS-based disks, like the venerable Windows 98SE Setup disk and others of its ilk.
The next task is to rip the boot files from this floppy, for which I currently have two methods.
Method 1 is more akin to treating a USB drive like a bootable floppy and most users will agree that
it is the easiest. However I will leave Method 2 (which treats the USB drive like a bootable CD)
below for any users who might have a special reason for needing it.
BACK UP ALL DATA ON THE USB DRIVE BEFORE PROCEEDING
IT WILL BE DELETED DURING FORMATTING

Method 1
Download HPUSBFW.EXE [432KB] which is a utility from Hewlett Packard for formatting and
making bootable USB drives (thanx Millie!). The file requires no installation and is designed for HP
equipment, although it ran on all non-HP equipment and drives tested. The original link for the file
is here.
Double clicking on the file runs the app..

Note the utility automatically detects the USB drive. Select the FAT file system, give it a Volume
label if required, select Quick Format, select Create a DOS startup disk and point the location to a
bootable
floppy
on
drive
A:\
The utility will format the drive
also command.com to the USB drive..

and

copy

the

boot

files io.sys, msdos.sys and

Note that to view these files under Windows Explorer, go to Tools | Folder Options | View tab |
Check Show hidden files and folders, uncheck Hide extensions for known file types and
uncheck Hide protected operating system files..

Add more DOS files and hardware drivers to the USB drive, as required. Finally configure the PC's
BIOS to boot to the USB drive first.

Method 2
This method uses a little utility called MKBT [29KB] from m'mann Bart Lagerweij over at NU2
Productions (top bloke, that Bart). Open a Command Prompt Window (Start | Run | cmd),
navigate to the directory where MKBT was extracted, and type the command:
mkbt
thus..
D:\Downloads\mkbt20>mkbt
*
Copy
D:\Downloads\mkbt20>

-c

a:
-c
bootsector

bootsect.bin
a:
mode

bootsect.bin
(-c)

Note that "a:" represents the drive which holds the bootable floppy. Once the command prompt
returns, there will be a boot sector stored in the file bootsect.bin - coolerino!

Preparing the USB drive

Format the thumb drive in the same format as the floppy disk, which is usually just plain old FAT.
FAT32 is better, but many USB thumb drives seem to have an aversion to it. The foul deed can be
performed through Windows Explorer - remember formatting destroys all data so copy it
elsewhere first. Right click the drive letter of the thumbdrive and select the option Format. Choose
the file system of choice (i.e. FAT) and click Start. Goodbye files..

Copying the boot sector file to the USB drive

Still got that command prompt window open? Good, 'cos we're back in black once again. This time
the
command
is:
mkbt

-x

like this..
D:\Downloads\mkbt20>mkbt
*
Expert
*
Warning
Size=0bytes
OEM="(=_[sIHC"

bootsect.bin
-x

bootsect.bin
mode
different
filesystem
VolLabel="NO
NAME"

I:
i:
(-x)
ID
FileSys=""

D:\Downloads\mkbt20>
Don't stuff up the drive letter which is shown above as I:. Yours is likely to be different. All being
well, after the smoke has cleared you will have a bootable boot sector on your thumbdrive.

The Last Bit

The
above
has
basically
given
the
USB
drive
the
equivalent
of io.sys, msdos.sys and command.comall in one neat little .bin file, just like a bootable CD-ROM
really. Now add any further usefulexternal DOS command files and utilities and any required
drivers. Note that if the donor boot floppy had an autoexec.bat or any other batch (*.bat) files or
a config.sys, check if these files are using absolute paths (i.e. A:\...) or relative paths (i.e. \...)
and change any commands to the latter. Any reference directly to the A: drive will screw things up
big-time during boot 'cos it won't be the A: drive any more.

The Last Last Bit (promised BIOS check)

Reboot the computer and go into the BIOS. Such entry is usually granted to those few who can
successfully remember the required special keyboard sequence, usually "Del", but popular
variations include "F1", "F2", "Insert", "F10" or using all your fingers and toes at once. A bit like
Twister
but
much
less
fun,
especially
if
you're
just
playing
with
yourself..
But moving right along, look for a BIOS setting referring to the Boot Order or something similar.
For some reason many BIOS's refer to USB/thumb drive as a "USB Removable Floppy Disk" or
"USB Zip Disk" or maybe you will find a uniquely creative variation. Anyway this is the one to be
first
in
the
boot
list.
If, despite your best efforts and considerable fiddling, your PC's BIOS does not seem to support
booting to USB, you could check to see if there's an update for the BIOS chip which would confer
this functionality. However note that flashing a BIOS is fraught with danger and if not perfomed

exactly as instructed, can result in a thoroughly cactussed BIOS chip (I know, I've been there and
so
have
a
few
chums
no
names
of
course.
Ian.)
Have

fun

USB

booting!

- A.

Put 30.01.2006 | Rev 17.12.2009 | Refresh Page |