30
« Last post by MTCAT on February 05, 2026, 01:28:41 PM »
Hi everyone,
I've been booting my TC 3.8.4 setup off 16 GB pen drives, I've successfully been able to make more clones of my original 16 GB pen drive, with dd, as long as it's onto another 16 GB drive.
If sdd is the "source" or original drive, and sde the new copy, I did
dd if=/dev/sdd of=/dev/sde conv=noerror,sync status=progress
And this has worked great, as long as it's 16 GB to 16 GB type of operation.
I have an expensive 4 GB industrial grade pen drive that I would like to use if possible but I haven't so far been able to get my system to boot up with the 4 GB pen drive.
Here's what I've tried so far;
1) I made a second copy of my original 16 GB pen drive, onto another 16 GB pen drive, with dd, as above.
2) I took that second copied 16 GB pen drive and shrank the partition (with gParted) to 3.7 GB.
3) I then tried various incarnations of "dd" after step (2) using the shrunk partition 16 GB drive copying onto the 4 GB drive but I haven't been able to get the 4 GB drive to boot, I get a "Boot error" right after the USB controllers get initialized and the BIOS is detecting USB devices. My son did film the boot up at 60 fps and I can see that the pen drive was recognized and configured (Cactus FlashCard *HiSpeed*), but right after that, I get "Boot error".
However, with my TC 3.8.4 booted up off a 16 GB pen drive, I can plug in and mount the 4GB drive and all seems well in that I can see the copied files on the 4 GB drive, dmesg output looks reasonable as pertains to the 4 GB drive, df returns 30 percent usage, etc.
I have also confirmed that I can boot up off the second copied 16 GB drive with the shrunk partition, so it should be an okay starting point (I hope) with which to make a 4 GB boot pen drive(?).
Here's the various things I've tried with dd.
Method A
dd if=/dev/sdd of=/dev/sde conv=noerror,sync status=progress
This worked away until we got to the 4 GB limit of sde, then dd complained of no space left on sde, and stopped, gracefully though, with a one record discrepancy at the end.
Method B
dd if=/dev/sdd of=/dev/sde bs=1M count=3700 status=progress
This worked away and exited fine with equal number of records in and out.
Method C
dd if=/dev/sdd1 of=/dev/sde1 conv=noerror,sync status=progress
This also worked fine in the sense that it didn't have any errors, but not sure that this even copied the boot sector?
But, in all cases, I get a "Boot error" when trying to boot up with the 4 GB pen drive.
I also tried writing all zeros to the 4 GB pen drive and then re-did Method A but still had the same result, "Boot error".
Appreciate any help or advice, I do have more industrial grade 16 GB drives on the way but will be another 6 weeks, would ideally get this 4 GB drive going in the meantime, not sure what to try next with the quest to make use of this expensive 4 GB pen drive.
Thanks,
David
[Edit]: Fixed code tag. Rich