Windows 10: Create bootable usb installer if install.wim > 4GB

Information
As discussed in tutorial DISM - Split install.wim file | Windows 10 Tutorials, it is not possible to create a bootable flash drive in fat32 format if the install.wim file is over 4GB in size. That tutorial presents a method to split the install.wim into smaller sub-files.
However, since Windows 10 1703, it is now possible to create a flash drive with multiple partitions which leads to an alternative solution.
Basically, two partitions are created i.e. a small (say 1GB) fat32 partition and a larger NTFS partition. The files from a standard installation iso are copied to the NTFS partition, and the standard install.wim file is replaced with the custom install.wim.
Similarly, all the files from the standard install.wim are copied to the fat32 partition except the files from the sources folder where only the boot.wim file is copied.

This guide does not superseded method in above tutorial but is an alternative method if using windows 10 1703 onwards

Here is a batch file that automates the copying process.

Here's How

You need at least an 8GB flash drive or larger depending on size of install.wim

1) Create folder on C drive called usbcreate (change drive and folder as you wish)

2) Create text file called ei.cfg with just two lines

[CHANNEL]
Retail

and save in folder c:\usbcreate

3) mount base iso as a drive and note Drive letter (It is assumed to be E: for this example)

4) copy custom install.wim to folder c:\usbcreate

5) create batch file called usbcreate.bat containing following text

Code: c: cd \usbcreate rd "baseiso" /s /q md "baseiso" xcopy E:\*.* "c:\usbcreate\baseiso\" /s /y diskpart /s "c:\usbcreate\diskpart.dat" label Q:USB-FAT32 label R:USB-NTFS xcopy "c:\usbcreate\install.wim" "c:\usbcreate\baseiso\sources\" /y xcopy "c:\usbcreate\ei.cfg" "c:\usbcreate\baseiso\sources\" /y xcopy "c:\usbcreate\baseiso\*.*" R:\ /s /y rd "c:\usbcreate\baseiso\sources\" /s /q md "c:\usbcreate\baseiso\sources\" xcopy "c:\usbcreate\baseiso\*.*" Q:\ /s /y /e xcopy "E:\sources\boot.wim" "Q:\sources\" /y[/quote] 6) Create a text file containing following text changing # as appropriate

Code: list disk (Replace # with drive number of usb flash drive) select disk # (Warning: Drive get wipes be sure you have selected correct drive) clean convert mbr create partition primary size=1000 create partition primary select partition 1 format fs=fat32 quick assign letter=Q active select partition 2 format fs=ntfs quick assign letter=R exit label Q:USB-FAT32 label R:USB-NTFS[/quote] 7) Insert flash drive and then right click usbcreate.bat and rum with admin rights.

:)

 

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