Comment 2 for bug 346700

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jruss (jruss) wrote : Re: [jaunty alpha 6+ daily] usb-creator creates incorrect free, persistent space; to /cdrom not /

This may be because vfat has a file size limitation of 4 GB. That is why it worked on your smaller 4 GB flash drive but failed on your larger drive when you tried to make the 7 GB file. Check the casper folder on your usb drive and see if there is a casper-rw file. If not then that is your problem. It wasn't created by usb-creator. Create the persistent usb again. Then look at ~/.usb-creator.log. My logs show an invalid size error from dd, and thus the casper-rw file isn't created.

This is related to: https://bugs.launchpad.net/ubuntu/+source/usb-creator/+bug/284085