Hello - I just finished testing Win32 Disk Imager v.5 in reference to this issue. Results are identical to what I initially reported when I opened this trouble ticket - Win32 Disk Imager is creating an image that is too big to write to identical media. To test, I first successfully captured an image that I have on a SanDisk 4GB Class 2 SD card. Size of the captured image was reported by Windows Explorer as 3.79 GB. I formatted an identical SanDisk 4GB Class 2 SD card using SD Formatter v3.1, and checked its capacity in Windows Explorer. Windows Explorer reported the capacity as 3.68GB. I attempted to write the captured image onto the newly formatted SD card; Win32 Disk Imager failed, reporting that there was not enough space on the SD card to write the image. This report also affects #932321. As the results of the latest test were identical to those that I initially reported, are you sure that the fixes were applied to the latest released version? There was an issue (reported in #187903) with missing DLL's in the version of .5 that was initially distributed. Knowing that configuration management is a tricky business at best, is is possible that the reported fixes did not make it into the second "release" of v.5? Just checking! If that's not the case, then the fixes applied to create v.5 to address #912259 (reclassified as a duplicate of #932321) did not solve the issue I reported. ----- Original Message ----- From: "Tobin Davis"