CREATE BARTPE FAT32 FLASH DRIVE (Great for 8+ gigabyte drives)

Prerequisite: Bartpe installed and successfully build an CD image

Method 1 ( from UBCD4WIN forum with a little modification).

Tools Required :
                         HP USB Disk Storage Format Tool
                          PE2USB
                          Windows 98SE Bootable Floppy Disk
                          GRUB4DOS 0.4.3
                          Winimage.exe

Steps:
1. use unzip attached file to a folder named x(any drive letter):\bartpe and open
SP27608.exe to install HP USB format tool      
2.Open the HP USB Disk Storage Format Tool, Select your USB key and set the file system to FAT32
             Check "Create a DOS startup disk"
             Tell it to use the DOS system files located at x:\bartpe\boot98se
             Click "Start" and let it go.
3.Open PEtoUSB.exe, select source folder from BARTPE folder
            Check "Enable File Copy" and select Overwrite Always from the drop-down
            Click "Start" and wait for the file copy to finish
4.Select all the files for GRUB4DOS and copy them to the root of the USB key.
            Allow it to overwrite config.sys
5.Open config.sys and edit the second line as following:
CODE
device=grub.exe --config-file="color black/cyan yellow/cyan;timeout 0;default 0;title find and load NTLDR of Windows NT/2K/XP;find --set-root /ntldr;chainloader /ntldr"
This will allow it to go straight to the NTLDR process.
Boot your USB key.

Method 2:

required tools: Flashboot

Steps:  simply open flashboot and check first radio button, then next and give the path of bartpe CD image, then next to select flash drive that will be used
            next step, you have options to format flash drive or HDD, then click on next and finish, your flash drive will be bootable