Hi Rob,

> - cleared any partition information:
>         dd if=/dev/zero of=/dev/sdb bs=8k count=2

Unnecessary destruction of working MBR...

> - created new partition-table:
>         fdisk /dev/sdb
>         - created primary partition 1 and marked as bootable

Only had to "marked as bootable" - rest is unnecessary.

> - create new FAT16 filesystem:
>         mkdosfs -F 16 /dev/sdb1

If you had not destroyed the partition information in earlier
steps, you could have used existing (better) FAT16 or FAT16
filesystem as created by the USB stick vendor.

> - tried to run "sys-freedos.pl":
>         sys-freedos.pl --disk=/dev/sdb
>         which reports: "not 512 bytes per sector"

Simple: You must write the boot sector to the partition, not the MBR.

perl sys-freedos.pl --disk=/dev/sdb1

Eric

PS: Some USB stick vendors use FAT32 instead of FAT16. Can be better.



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