http://www.msfn.org/board/Multiple_Partition_USB_Stick_Multi_Boo_t69211.html

I wanted several operating systems on a USB stick and after many hours messing with syslinux, memdisk, grub4dos, xosl, freedos, avlgomgr, acronis os selector, ranish partition manager. I have succumbed. I first started out wanting to boot an iso off USB and ran into trouble loading large img with memdisk which I found out is due to a bug in msdos so I used freedos but things didn't work out as planned and it's a similar woe story's with the rest. Acronis os selector lets you boot multiple os from one partition from different folders but don't work great when it comes to dos.

I have 5 partitions on my USB stick and using the boot loader BootIt NG http://www.bootitng.com/bootitng.html This is a 30 day trial.

Now I wasn't happy just putting one os on my USB stick. I wanted linux and diagnostic tools etc.

We want your first partition dos bootable so run HP USB Disk Storage Format Tool. I'm using version 2.1.8. Select your drive letter of your USB device and select "Create a DOS startup disk" and browse to your 98 boot disk folder. Click Start. Your USB will be formatted and 3 files will be copied from your dos startup files. You need to manually copy the rest of the 98 boot files to your USB drive.

You can now resize the drive (mines 512MB) and create multiple partitions. All partition software now sees it as a fixed disk. I used acronis disk director and resized the partition keeping the first dos bootable partition intact and made another 4 fat partitions so I had 5 in total.

Make sure your format all partitions as Primary not Logical.

Copy dos,ghost whatever files to your dos partititon and copy your bartpe files to the bartpe partititon.

Check you have the 2 files mkbt.exe & pe2usb.bin in your pebuilder folder. Download Pe2usb if not. Open up a cmd box in your pebuilder dir and run the command:

mkbt.exe -x pe2usb.bin N:

N being the letter of your bartpe partition.

Reboot and keep your USB stick in and boot off the dos cd or floppy.

Type the command sys drive: drive being the letter of your dos partititon.

Run spfdisk.exe in dos. Create the menu to boot both partitions in spfdisk. Save the changes.