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It is not exactly 1:1 (but I'd say it's close)- Since the compression is different between the OS (NT compression) and the WIM compression. Since you're using USB disk that is twice as big as your image size, the only thing that I can think of is the Filesystem limitation. If the USB disk is formatted with FAT, the tool will only be able to write/append the file up to the limit of 4 GB.

 

HP released a new ThinState tool that format the USB disk with NTFS. I believe the version that support NTFS is 6.0.0.38 it should be on the latest WES 7e image. To check version: right client on the file c:\program files\hewlett-packard\thinstate capture\hpdepmgr.exe -> click properties -> click details tab.

 

Here is another way to "Fix" the USB disk from your desktop.

1. Copy the disk content to a folder on your PC

2. open a cmd prompt

3. run diskpart

4. list disk   --> to view your USB disk

5. select disk [your USB disk number]

6. clean      --> this will format or clean your disk including your partition info

7. create partition primary

8. select partition 1

9. active     --> this will make it bootable.

10. format quick fs=ntfs lable="ThinState"

11. assign letter=[your USB disk letter]

12. exit.

13. Now restore the content of the USB disk from your PC.

 

Another way is to download the latest image and use the tool to format the USB disk automatically.

HP Recommended

Thanks for sharing!

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Although I am an HP employee, I am speaking for myself and not for HP.
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