I just tried it again: I zero'ed out the first 50 MB of the stick,
repartitioned again

Disk /dev/sdc: 1028 MB, 1028653056 bytes
32 heads, 62 sectors/track, 1012 cylinders
Units = cylinders of 1984 * 512 = 1015808 bytes
Disk identifier: 0x000826dc

   Device Boot      Start         End      Blocks   Id  System
/dev/sdc1   *           1        1012     1003873    6  FAT16


same USB stick, same .iso, same usb-creator, same mode (non-persistent). Maybe 
the previous partition/header/etc. was wedged somehow.

I still have the full image from the stick that didn't boot. Any way to
compare them in a sensible way?

-- 
created USB stick does not boot (worked two weeks ago)
https://bugs.launchpad.net/bugs/348078
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