Posted on August 16, 2010 at 9:59 am - by Corey DeGrandchamp
Guide: Create the Ultimate USB Drive

Ever since I created my USB drive and tweaked it with a menu system, I’ve been getting asked how to do it, and what programs I’ve used, well keeping a long story short, I basically spent nearly three days using different menu systems, including Portable Apps Menu, geek.menu, and a few others before finally deciding on PStart.
PStart is definitely the most minimalistic option, but it works out well. It’s very light-weight and has ALL its settings and information stored in one single XML file. So the program itself is easily kept (and managed) on the root of your drive.
The first thing you’ll want to do is download PStart. Be sure to get the non U3 edition listed.
After you download it, install it to your thumb drive, which is pretty self-explanatory. After that, open your thumb drive and you’ll see PStart.exe in the root of the drive. I personally renamed PStart.exe just to Menu.exe, but if you do something similar to this, you will also need to rename the XML file it creates (when it runs for the first time) to the same name. Example would be Menu.exe and Menu.xml both need to reside in the same folder. If you have Menu.exe and PStart.xml you’re configuration won’t work. The simpler solution here is just to leave it as PStart.exe unless you’re picky.
After this, you can create an autorun.inf file that will let you launch the menu automatically. Keep in mind that Windows 7 has disabled autorun files from functioning off USB media, so this only works for Windows XP and Windows Vista, but is still handy to have in case you ever plug into an XP/Vista machine.
My autorun.inf file looks like this:
[autorun]
LABEL=Corey DeGrandchamp
ICON=.\CruzerMicro.icoACTION=Menu
OPEN=.\PStart.exeshell\Menu\command=PStart.exe
shell\Lost\command=Lost.exe
This is how it looks when it’s working properly.

The LABEL and ICON attributes will affect how the drive looks in “My Computer” when it’s plugged in. I have a custom icon for my Cruzer Micro that I use, so I have that assigned also.
If you’re wondering what the “Lost.exe” portion of that file is, we will get to that later!
Once you have your autorun configured, and set a custom icon (if you wish), then it’s time to move onto installing apps!
Most apps I have are from the PortableApps suite of applications, and they can be downloaded individually from the AutoIt. We’ll specific component we’ll use is “Aut2Exe”. This will convert our .au3 file into a .exe to be run on any computer running Windows. I ended up using a custom icon for this as well, you can grab my icon below. Just right click and save it.
The Aut2Exe is pretty easy to use, just feed it your .au3 file and the .ico file, and tell it where to make the .exe file. I put mine in the root of my USB drive and tied it into the autorun file above.
Next up on the list, is a simple batch script that checks your USB drive for errors.
@ECHO OFF
CLS
COLOR 0A
ECHO.
ECHO.
ECHO.
TITLE Checking %2 USB drive for errors…
ECHO Checking USB drive for errors…
ECHO.
CHKDSK %1
ECHO.
PAUSE

Just copy/paste the above and save it as check.bat and make a slot in your PStart menu for this as well.
And the last item is a way to eject a USB drive… This one is a bit more complicated… It will prompt you to close all open files and programs, you do NOT have to close the PStart menu before using this, just any open files, such as a portable application or a document from your USB drive. It’s just a friendly reminder, if you don’t close them, the drive will just fail to eject properly. After it prompts you to close the programs, it will wait for any key input to confirm you’ve closed them, then it will instruct the user to wait for the confirmation message that the drive has been ejected before removing the drive. See the screenshots below for more details.
This isn’t a simple copy/paste job for this, so I’ve packaged up everything that I’ve used as a .zip file. Just put it somewhere on your thumb drive and point your PStart menu item to the Eject.bat file.
Here’s the download: USB_Disk_Ejector.zip
That’s about all I have for you for right now. If you have any questions at all leave them in the comments here and I’ll get back to you as soon as possible.



