Win10 Setup Disk [Works with UEFI with Secure Boot / BIOS / Install.wim over 4 GB]

Yes, earlier versions of Windows do not support reading and creating multiple partitions on removable storage devices. MS only started support for multiple partitions on removable media on Windows 10 Version 1703.

 

For a Windows ISO with an install.wim under 4 GB you just need to format your USB disk to FAT32 and copy the contents of your Windows ISO to the disk
or
you can use this automated script



What the script does

1. Converts your USB disk to MBR scheme.
   
2. Creates a FAT32 active partition.
3. Mounts your Windows ISO.
   
4. Copies the entire contents of the Windows ISO to the USB disk.

Script (Updated Feb 19, 2021)

Code:

<# : standard way of doing hybrid batch + powershell scripts
@title Setup Disk @ forums.mydigitallife.net &color f0
@set "__ARGS__=%*" &powershell -noprofile "$ScriptPath='%~f0';iex((Get-Content('%~f0') -Raw))" &exit/b
#>
#
#   Website: https://forums.mydigitallife.net/threads/win10-setup-disk-for-uefi-or-bios-uefi-with-secure-boot-install-wim-over-4-gb.79268/
#
#   This script must be executed with admin privilege
#
#   Test Administrator privileges
If (-NOT ([Security.Principal.WindowsPrincipal] [Security.Principal.WindowsIdentity]::GetCurrent()).IsInRole([Security.Principal.WindowsBuiltInRole] "Administrator"))
{
    $uac_error="Elevating UAC for Administrator Privileges failed"
    #   The following test is to avoid infinite looping if elevating UAC for Administrator Privileges failed
    if ($env:__ARGS__ -eq $uac_error) {
    read-host "$uac_error`r`nRight click on the script and select ""Run as administrator""`r`nPress Enter to exit...";exit}
#   Restart the script to get Administrator privileges and exit
                                                                                   
    Start-Process "$ScriptPath" $uac_error -Verb runAs; exit
}
$pswindow = $host.ui.rawui          # create a reference to the console’s UI.RawUI child object
$pswindow.windowtitle = ([string]($pswindow.windowtitle -split "^.*  ")).trim() ; $ShortTitle=($pswindow.windowtitle -split " @ .*")[0]
#
Add-Type -AssemblyName System.Windows.Forms # Load the class System.Windows.Forms
#
# Filebrowser dialog object
$FileBrowser = New-Object System.Windows.Forms.OpenFileDialog -Property @{
    Multiselect = $false # One file can be chosen
    Filter = 'ISO images (*.iso)|*.iso' # Select only iso files
}
#
Function MsgBox {[System.Windows.Forms.MessageBox]::Show($Args[0],$ShortTitle,$Args[1],$Args[2])}
#
clear-host
$USB=$Null
$Form=New-Object System.Windows.Forms.Form # Create the screen form (window)
$Form.TopMost = $True
# Set the title and size of the window:
$Form.Text=$ShortTitle
$Form.Font='Consolas,10'
$Form.Width=420 ; $Form.Height=265
$Form.StartPosition = "CenterScreen"
$Form.SizeGripStyle = "Hide"
[System.Windows.Forms.Application]::EnableVisualStyles();

# Create a drop-down list and fill it
$USBDiskList=New-Object System.Windows.Forms.ComboBox
$USBDiskList.DropDownStyle=[System.Windows.Forms.ComboBoxStyle]::DropDownList;
$USBDiskList.Location=New-Object System.Drawing.Point(20,50)
$USBDiskList.Size=New-Object System.Drawing.Size(363,22)
$Form.Controls.Add($SelectUSBDiskList)
$USBDisks=@() # array with USB disk number
#
$Disks=$Null;While (!$Disks){
    If(!($Disks=Get-Disk | Where-Object {($_.BusType -eq "USB") -and ($_.OperationalStatus -eq "Online")})){

               
        if((MsgBox "Please plug in your USB disk first. `n`nClick OK to continue." "OKCancel" "Information") -eq "Cancel") {exit}}}

$USBDisk=New-Object System.Windows.Forms.Label # Put the USB Disk label on the form
$USBDisk.Location=New-Object System.Drawing.Point(20,30)
$USBDisk.Text="USB Disk"                     
$USBDisk.Size=New-Object System.Drawing.Size(200,20)
$Form.Controls.Add($USBDisk)

$ISOImage=New-Object System.Windows.Forms.Label # Put the ISO Image label on the form
$ISOImage.Location=New-Object System.Drawing.Point(20,95)                 
$ISOImage.Size=New-Object System.Drawing.Size(200,20)
$ISOImage.text="ISO Image"
$Form.Controls.Add($ISOImage)

$ISOFile=New-Object System.Windows.Forms.Label # Put the ISO file name on the form
$ISOFile.Location=New-Object System.Drawing.Point(20,115)
$ISOFile.Text=" "
$ISOFile.Size=New-Object System.Drawing.Size(364,24)
$ISOFile.Backcolor = [System.Drawing.Color]::White
$ISOFile.BorderStyle = [System.Windows.Forms.BorderStyle]::FixedSingle
$Form.Controls.Add($ISOFile)

$CancelButton=New-Object System.Windows.Forms.Button # Put the Cancel button on the form
$CancelButton.Location=New-Object System.Drawing.Point(285,180)
$CancelButton.Text="Cancel"                                                           
$CancelButton.Size=New-Object System.Drawing.Size(100,26)
$Form.Controls.Add($CancelButton)
$CancelButton.DialogResult = [System.Windows.Forms.DialogResult]::Cancel

$SelectISOButton=New-Object System.Windows.Forms.Button # Put the Select ISO button on the form
$SelectISOButton.Location=New-Object System.Drawing.Point(175,180)
$SelectISOButton.Text="Select ISO"                                                                   
$SelectISOButton.Size=New-Object System.Drawing.Size(100,26)
$Form.Controls.Add($SelectISOButton)
$CreateDiskButton=New-Object System.Windows.Forms.Button # Put the Create Disk button on the form
$CreateDiskButton.Location=New-Object System.Drawing.Point(65,180)
$CreateDiskButton.Text="Create Disk"                                 
                                     
$CreateDiskButton.Size=New-Object System.Drawing.Size(100,26)
$Form.Controls.Add($CreateDiskButton)
$CreateDiskButton.Enabled = $false
$CreateDiskButton.DialogResult = [System.Windows.Forms.DialogResult]::OK

$SelectISOButton.Add_Click({
    If ($FileBrowser.ShowDialog() -ne "Cancel"){ # if Cancel, just ignore
        $Global:ImagePath = $FileBrowser.filename    # return the file name
        $ISOFile.Text= Split-Path -Path $ImagePath -leaf # extract filename and extension (iso)
        if (($ISOFile.Text).length -gt 44) {$ISOFile.Text = $ImagePath.PadRight(100," ").substring(0,43)+"..."}
        $CreateDiskButton.Enabled = $true
        $CreateDiskButton.Focus()}})

Foreach ($USBDisk in $Disks) {
    $FriendlyName=($USBDisk.FriendlyName).PadRight(40," ").substring(0,39)
    $USBDisks+=$USBDisk.DiskNumber
    $USBDiskList.Items.Add(("{0,-39}{1:n2} GB" -f $FriendlyName,($USBDisk.Size/1GB)))|out-null
    $Partitions = Get-Partition | Where-Object { $_.DiskNumber -eq $USBDisk.DiskNumber}
    If ($Partitions) {
        Foreach ($Partition in $Partitions) {
        $Volumes=get-volume | Where-Object {$Partition.AccessPaths -contains  $_.path }
            Foreach ($Volume in $Volumes) {
                $USBDisks+=$USBDisk.DiskNumber
                $USBDiskList.Items.Add(("{0,0}({1,1}:){2,-32}[{3:n2} GB]" -f " ", ($Partition.DriveLetter), $Volume.FileSystemLabel.PadRight(25," ").substring(0,25), ($Partition.Size/1GB)))|out-null
            }
        }
    }
}
$form.Controls.Add($USBDiskList)
$USBDiskList.SelectedIndex=0
#
$Groupbox=New-Object System.Windows.Forms.Groupbox # Add a group box on the form
$Groupbox.Location=New-Object System.Drawing.Point(7,0)
$Groupbox.Text=""
$Groupbox.Size=New-Object System.Drawing.Size(390,220)
$Form.Controls.Add($Groupbox)
#                                                                               
if($form.ShowDialog() -eq "Cancel") {MsgBox "The script was cancelled." "OK" "Information"|out-Null;exit}
#
# At this point the mounted USB disk and the iso image file path are defined
#
$USB=$USBDisks[$USBDiskList.SelectedIndex]
#
If((MsgBox "WARNING! `n`nYour USB disk will be converted to MBR scheme, repartitioned and reformatted.`n`nAll partitions and data currently stored in the USB disk will be erased.`r`n`r`nAre you sure you want to continue?" "YESNO" "Warning") -eq "NO"){exit}
# Mount the image file if not already mounted and get the drive letter
#
#   Check if iso already mounted by getting driveletter
If($ISO=(Get-DiskImage -ImagePath $ImagePath | Get-Volume).DriveLetter){$Mounted=$True}    Else
#    Mount iso and get drive letter
             
    {$Mounted=$False; Mount-DiskImage -ImagePath $ImagePath -StorageType ISO |out-null
     If(!($ISO=(Get-DiskImage -ImagePath $ImagePath | Get-Volume).DriveLetter)){Exit}}
$ISO=$ISO+":"                        
#                                                                                                                                                                                                                                                                                                       
Clear-Host
#    Clear the USB stick
Clear-Disk $usb -RemoveData -RemoveOEM -Confirm:$false
set-disk $usb -partitionstyle mbr
Stop-Service ShellHWDetection -erroraction silentlycontinue|out-null
#    Create the fat32 boot partition
$usbfat32=(New-Partition -DiskNumber $usb -UseMaximumSize -AssignDriveLetter -IsActive | Format-Volume -FileSystem FAT32 -NewFileSystemLabel "Win10XPE").DriveLetter + ":"
robocopy $iso $usbfat32 /e

# Eject the mounted iso image if it was loaded by the script
If(!$Mounted){DisMount-DiskImage -ImagePath $ImagePath |out-null}
MsgBox (($ShortTitle -split " @.*")[0]+" completed successfully.") "OK" "Information" |Out-Null;exit

 

How is it now?

 

Thanks @rpo for continuing to come to the rescue

 

Could be your install.wim is above the 4GB limit.

 

Mount your Windows ISO. Navigate to "sources" folder. Locate "install.wim". Right click "Properties".



Usually this is the error you get when the install.wim is beyond the 4GB limit.




Win10 Installation Disk 1.9.2 is for install.wims over 4GB

​

 

To avoid confusion...


Win10 Setup Disk 1.9.2 [For UEFI or BIOS / UEFI with Secure Boot / Install.wim over 4 GB]


Setup disk [For UEFI or BIOS / UEFI with Secure Boot / Install.wim under 4 GB]

 

@rpo I don't know why I only noticed this now
when booting into uefi the windows cover the entire screen

 

It's happening only with 20H1