Create Bootable Hirens CD on USB using Linux

Overview

This howto outlines the procedures for creating a bootable version of Hirens on a USB drive using Linux. The problem arises when attempting to create the the bootable USB using the traditional (and generally reliable) isohybrid + dd approach. There is one fine which needs to be renamed, and in order to do that, we must unpack the ISO, make that change, and then repack the ISO prior to creating our bootable thumb drive.

Procedure

After downloading Hirens Boot CD, unzip the file, and mount the ISO image:

unzip Hirens-BootCD-15.2.zip
mount -t iso9660 -o loop Hirens-BootCD-15.2.iso /mnt/myCD

Now copy the contents of that mounted image to a temporary directory (the mounted ISO is read-only):

cd /tmp/someDir
rsync -av /mnt/myCD/* .

Your resulting file directory listing will look something like this:

autorun.inf  changes.txt  HBCD  HBCDMenu.cmd  HBCD.txt

Navigate to the HBCD directory, which will have the following contents:

cd
ls
Boot  Dos  grldr  HBCDMenu.exe  isolinux.bin  menu-custom.lst  menu.lst  Programs  isolinux.cfg  XP

Now merely change the file “isolinux.cfg” to “syslinux.cfg”:

mv isolinux.cfg syslinux.cfg

That should do it for the changes. Now repackage the ISO from the root directory where you unzipped the files:

cd /tmp/myCD
mkisofs -o /tmp/myHIRENS.iso -b HBCD/isolinux.bin -c HBCD/boot.cat -no-emul-boot -boot-load-size 4 -boot-info-table -J -R -V "Hirens Boot CD" .

Now you can follow the procedure for creating a bootable USB drive on Linux (lets assume our USB drive is /dev/sdd):

cd /tmp
isohybrid myHIRENS.iso
dd if=myHIRENS.iso of=/dev/sdd
sync

Now test, you should be done!

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