setup an existing FAT16 formatted USB key: $ syslinux /dev/sda1 $ mount /dev/sda1 x/ $ echo "default histar" > x/syslinux.cfg then just copy over a HiStar image: $ make $ cp /obj/boot/bimage.init x/histar if booting errors or hangs: install a valid MBR: $ install-mbr /dev/sda check that /dev/sda1 is marked bootable in the partition table: $ fdisk /dev/sda make sure BIOS is booting USB key in "USB-HDD" mode..see http://syslinux.zytor.com/usbkey.php for hints. in cygwin: $ syslinux.exe -m -a f: $ echo 'default histar' > /cygdrive/f/syslinux.cfg $ cp ~/jos64/obj/boot/bimage.init /cygdrive/f/histar