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[Tutorial] How to create a bootable USB flash drive in fat32 format if the install.wim file exceeds 4 GB ?
haris_sane69 posted a topic in Software ChatHello everyone, As you guys already know that it is not possible to create a bootable USB flash drive in FAT32 format if the install.wim on the ISO exceeds 4 GB in size, which means the only File System available is NTFS and if this is used, the Bootable USB will not pass Secure Boot. 1) To get around this we need to make a non-Bootable FAT32 formatted USB Flash Drive using Rufus. Make sure the options are as follows in Rufus: Boot selection : Non bootable ; Partition scheme : GPT ; Target system : BIOS or UEFI ; Volume label : Windows Version & File system : FAT32 (Default) a) Select Start. b) Select OK to format the USB flash drive. c) When done Rufus will say READY, you may now close Rufus. d) In Windows Explorer you should have a blank FAT32 formatted USB Flash Drive. e) Delete the autorun files on it. 2) Now manually create bootable USB: a) In Windows Explorer, right click the ISO file. b) Then select Mount. c) Copy all the files & folders to the USB except sources folder which contain install.wim. d) Then create a new folder on the USB called sources. e) Copy all the files in the sources folder on the ISO except the install.wim onto the USB Flash Drive. 3) Split Install.wim into Multiple Install.swm Files: a) Copy the install.wim directly to the C:\Drive. b) Select Continue when asked to provide administrative conditions. We will now split the install.wim into multiple install.swm files. c) Right click the start button and select Windows PowerShell (Admin). d) Accept the User Account Control Prompt. e) Copy and paste the following command into the PowerShell Window, then press [Enter]. Dism /Split-Image /ImageFile:C:\install.wim /SWMFile:C:\install.swm /FileSize:4000 f) When the Operation has Completed Successfully close the Power Shell Window. g) This will create two (or more) install.swm files. h) Copy these to the sources folder of the Bootable USB flash drive. That's all. CREDITS: @philipyip