Win11 Creator USB and Log Fixes (#4139)

* initial usb fixes

* fix full button width

* Cleanup and Verbose output for copy

* expand ui and fix clean and reset

* Add minimal driver injection

* initial driver support

* fix verbage

* fix syntax error

* create log file on iso generation

* inject to boot.wim for install

* fix single driver install issues

* fix first run probs

* cleanup injection

* improve clean up

* Fix OSCDIMG output and cleanup comments

* Fix Scrollviewer in Status Log

* large drive support and change to Exfat

* Fix BOOT for older UEFI and Add error checks for small usb drives

* fix single usb drive error

.github/workflows/docs.yaml

@@ -47,7 +47,7 @@ jobs:
       - name: Setup Pages
         id: pages
         uses: actions/configure-pages@v5
-        
+
       - name: Generate Dev Docs from JSON
         shell: pwsh
         run: |

functions/private/Invoke-WinUtilISOScript.ps1

@@ -4,50 +4,38 @@ function Invoke-WinUtilISOScript {
         Applies WinUtil modifications to a mounted Windows 11 install.wim image.
 
     .DESCRIPTION
-        Performs the following operations against an already-mounted WIM image:
+        Removes AppX bloatware and OneDrive, optionally injects all drivers exported from
+        the running system into install.wim and boot.wim (controlled by the
+        -InjectCurrentSystemDrivers switch), applies offline registry tweaks (hardware
+        bypass, privacy, OOBE, telemetry, update suppression), deletes CEIP/WU
+        scheduled-task definition files, and optionally writes autounattend.xml to the ISO
+        root and removes the support\ folder from the ISO contents directory.
 
-        1. Removes provisioned AppX bloatware packages via DISM.
+        All setup scripts embedded in the autounattend.xml <Extensions><File> nodes are
-        2. Removes OneDriveSetup.exe from the system image.
+        written directly into the WIM at their target paths under C:\Windows\Setup\Scripts\
-        3. Loads offline registry hives (COMPONENTS, DEFAULT, NTUSER, SOFTWARE, SYSTEM)
+        to ensure they survive Windows Setup stripping unrecognised-namespace XML elements
-           and applies the following tweaks:
+        from the Panther copy of the answer file.
-             - Bypasses hardware requirement checks (CPU, RAM, SecureBoot, Storage, TPM).
-             - Disables sponsored-app delivery and ContentDeliveryManager features.
-             - Enables local-account OOBE path (BypassNRO).
-             - Writes autounattend.xml to the Sysprep directory inside the WIM and,
-               optionally, to the ISO/USB root so Windows Setup picks it up at boot.
-             - Disables reserved storage.
-             - Disables BitLocker device encryption.
-             - Hides the Chat (Teams) taskbar icon.
-             - Disables OneDrive folder backup (KFM).
-             - Disables telemetry, advertising ID, and input personalization.
-             - Blocks post-install delivery of DevHome, Outlook, and Teams.
-             - Disables Windows Copilot.
-             - Disables Windows Update during OOBE.
-        4. Deletes unwanted scheduled-task XML definition files (CEIP, Appraiser, etc.).
-        5. Removes the support\ folder from the ISO contents directory (if supplied).
 
-        Mounting and dismounting the WIM is the responsibility of the caller
+        Mounting/dismounting the WIM is the caller's responsibility (e.g. Invoke-WinUtilISO).
-        (e.g. Invoke-WinUtilISO).
 
     .PARAMETER ScratchDir
         Mandatory. Full path to the directory where the Windows image is currently mounted.
-        Example: C:\Users\USERNAME\AppData\Local\Temp\WinUtil_Win11ISO_20260222\wim_mount
 
     .PARAMETER ISOContentsDir
-        Optional. Root directory of the extracted ISO contents.
+        Optional. Root directory of the extracted ISO contents. When supplied,
-        When supplied, autounattend.xml is also written here so Windows Setup picks it
+        autounattend.xml is written here and the support\ folder is removed.
-        up automatically at boot, and the support\ folder is deleted from that location.
 
     .PARAMETER AutoUnattendXml
-        Optional. Full XML content for autounattend.xml.
+        Optional. Full XML content for autounattend.xml. If empty, the OOBE bypass
-        In compiled winutil.ps1 this is the embedded $WinUtilAutounattendXml here-string;
+        file is skipped and a warning is logged.
-        in dev mode it is read from tools\autounattend.xml.
+
-        If empty, the OOBE bypass file is skipped and a warning is logged.
+    .PARAMETER InjectCurrentSystemDrivers
+        Optional. When $true, exports all drivers from the running system and injects
+        them into install.wim and boot.wim index 2 (Windows Setup PE).
+        Defaults to $false.
 
     .PARAMETER Log
-        Optional ScriptBlock used for progress/status logging.
+        Optional ScriptBlock for progress/status logging. Receives a single [string] argument.
-        Receives a single [string] message argument.
-        Defaults to { param($m) Write-Output $m } when not supplied.
 
     .EXAMPLE
         Invoke-WinUtilISOScript -ScratchDir "C:\Temp\wim_mount"
@@ -62,24 +50,19 @@ function Invoke-WinUtilISOScript {
     .NOTES
         Author  : Chris Titus @christitustech
         GitHub  : https://github.com/ChrisTitusTech
-        Version : 26.02.22
+        Version : 26.03.02
     #>
     param (
         [Parameter(Mandatory)][string]$ScratchDir,
-        # Root directory of the extracted ISO contents. When supplied, autounattend.xml
-        # is written here so Windows Setup picks it up automatically at boot.
         [string]$ISOContentsDir = "",
-        # Autounattend XML content. In compiled winutil.ps1 this comes from the embedded
-        # $WinUtilAutounattendXml here-string; in dev mode it is read from tools\autounattend.xml.
         [string]$AutoUnattendXml = "",
+        [bool]$InjectCurrentSystemDrivers = $false,
         [scriptblock]$Log = { param($m) Write-Output $m }
     )
 
-    # ── Resolve admin group name (for takeown / icacls) ──────────────────────
     $adminSID   = New-Object System.Security.Principal.SecurityIdentifier('S-1-5-32-544')
     $adminGroup = $adminSID.Translate([System.Security.Principal.NTAccount])
 
-    # ── Local helpers ─────────────────────────────────────────────────────────
     function Set-ISOScriptReg {
         param ([string]$path, [string]$name, [string]$type, [string]$value)
         try {
@@ -100,15 +83,37 @@ function Invoke-WinUtilISOScript {
         }
     }
 
-    # ═════════════════════════════════════════════════════════════════════════
+    function Add-DriversToImage {
-    #  1. Remove provisioned AppX packages
+        param ([string]$MountPath, [string]$DriverDir, [string]$Label = "image", [scriptblock]$Logger)
-    # ═════════════════════════════════════════════════════════════════════════
+        & dism /English "/image:$MountPath" /Add-Driver "/Driver:$DriverDir" /Recurse 2>&1 |
+            ForEach-Object { & $Logger "  dism[$Label]: $_" }
+    }
+
+    function Invoke-BootWimInject {
+        param ([string]$BootWimPath, [string]$DriverDir, [scriptblock]$Logger)
+        Set-ItemProperty -Path $BootWimPath -Name IsReadOnly -Value $false -ErrorAction SilentlyContinue
+        $mountDir = Join-Path $env:TEMP "WinUtil_BootMount_$(Get-Random)"
+        New-Item -Path $mountDir -ItemType Directory -Force | Out-Null
+        try {
+            & $Logger "Mounting boot.wim (index 2) for driver injection..."
+            Mount-WindowsImage -ImagePath $BootWimPath -Index 2 -Path $mountDir -ErrorAction Stop | Out-Null
+            Add-DriversToImage -MountPath $mountDir -DriverDir $DriverDir -Label "boot" -Logger $Logger
+            & $Logger "Saving boot.wim..."
+            Dismount-WindowsImage -Path $mountDir -Save -ErrorAction Stop | Out-Null
+            & $Logger "boot.wim driver injection complete."
+        } catch {
+            & $Logger "Warning: boot.wim driver injection failed: $_"
+            try { Dismount-WindowsImage -Path $mountDir -Discard -ErrorAction SilentlyContinue | Out-Null } catch {}
+        } finally {
+            Remove-Item -Path $mountDir -Recurse -Force -ErrorAction SilentlyContinue
+        }
+    }
+
+    # ── 1. Remove provisioned AppX packages ──────────────────────────────────
     & $Log "Removing provisioned AppX packages..."
 
     $packages = & dism /English "/image:$ScratchDir" /Get-ProvisionedAppxPackages |
-        ForEach-Object {
+        ForEach-Object { if ($_ -match 'PackageName : (.*)') { $matches[1] } }
-            if ($_ -match 'PackageName : (.*)') { $matches[1] }
-        }
 
     $packagePrefixes = @(
         'AppUp.IntelManagementandSecurityStatus',
@@ -155,25 +160,46 @@ function Invoke-WinUtilISOScript {
         'MicrosoftTeams'
     )
 
-    $packagesToRemove = $packages | Where-Object {
+    $packages | Where-Object { $pkg = $_; $packagePrefixes | Where-Object { $pkg -like "*$_*" } } |
-        $pkg = $_
+        ForEach-Object { & dism /English "/image:$ScratchDir" /Remove-ProvisionedAppxPackage "/PackageName:$_" }
-        $packagePrefixes | Where-Object { $pkg -like "*$_*" }
+
-    }
+    # ── 2. Inject current system drivers (optional) ───────────────────────────
-    foreach ($package in $packagesToRemove) {
+    if ($InjectCurrentSystemDrivers) {
-        & dism /English "/image:$ScratchDir" /Remove-ProvisionedAppxPackage "/PackageName:$package"
+        & $Log "Exporting all drivers from running system..."
+        $driverExportRoot = Join-Path $env:TEMP "WinUtil_DriverExport_$(Get-Random)"
+        New-Item -Path $driverExportRoot -ItemType Directory -Force | Out-Null
+        try {
+            Export-WindowsDriver -Online -Destination $driverExportRoot | Out-Null
+
+            & $Log "Injecting current system drivers into install.wim..."
+            Add-DriversToImage -MountPath $ScratchDir -DriverDir $driverExportRoot -Label "install" -Logger $Log
+            & $Log "install.wim driver injection complete."
+
+            if ($ISOContentsDir -and (Test-Path $ISOContentsDir)) {
+                $bootWim = Join-Path $ISOContentsDir "sources\boot.wim"
+                if (Test-Path $bootWim) {
+                    & $Log "Injecting current system drivers into boot.wim..."
+                    Invoke-BootWimInject -BootWimPath $bootWim -DriverDir $driverExportRoot -Logger $Log
+                } else {
+                    & $Log "Warning: boot.wim not found — skipping boot.wim driver injection."
+                }
+            }
+        } catch {
+            & $Log "Error during driver export/injection: $_"
+        } finally {
+            Remove-Item -Path $driverExportRoot -Recurse -Force -ErrorAction SilentlyContinue
+        }
+    } else {
+        & $Log "Driver injection skipped."
     }
 
-    # ═════════════════════════════════════════════════════════════════════════
+    # ── 3. Remove OneDrive ────────────────────────────────────────────────────
-    #  2. Remove OneDrive
-    # ═════════════════════════════════════════════════════════════════════════
     & $Log "Removing OneDrive..."
     & takeown /f "$ScratchDir\Windows\System32\OneDriveSetup.exe" | Out-Null
     & icacls    "$ScratchDir\Windows\System32\OneDriveSetup.exe" /grant "$($adminGroup.Value):(F)" /T /C | Out-Null
     Remove-Item -Path "$ScratchDir\Windows\System32\OneDriveSetup.exe" -Force -ErrorAction SilentlyContinue
 
-    # ═════════════════════════════════════════════════════════════════════════
+    # ── 4. Registry tweaks ────────────────────────────────────────────────────
-    #  3. Registry tweaks
-    # ═════════════════════════════════════════════════════════════════════════
     & $Log "Loading offline registry hives..."
     reg load HKLM\zCOMPONENTS "$ScratchDir\Windows\System32\config\COMPONENTS"
     reg load HKLM\zDEFAULT    "$ScratchDir\Windows\System32\config\default"
@@ -222,14 +248,37 @@ function Invoke-WinUtilISOScript {
     Set-ISOScriptReg 'HKLM\zSOFTWARE\Microsoft\Windows\CurrentVersion\OOBE' 'BypassNRO' 'REG_DWORD' '1'
 
     if ($AutoUnattendXml) {
-        # ── Place autounattend.xml inside the WIM (Sysprep) ──────────────────
+        try {
-        $sysprepDest = "$ScratchDir\Windows\System32\Sysprep\autounattend.xml"
+            $xmlDoc = [xml]::new()
-        Set-Content -Path $sysprepDest -Value $AutoUnattendXml -Encoding UTF8 -Force
+            $xmlDoc.LoadXml($AutoUnattendXml)
-        & $Log "Written autounattend.xml to Sysprep directory."
+
+            $nsMgr = New-Object System.Xml.XmlNamespaceManager($xmlDoc.NameTable)
+            $nsMgr.AddNamespace("sg", "https://schneegans.de/windows/unattend-generator/")
+
+            $fileNodes = $xmlDoc.SelectNodes("//sg:File", $nsMgr)
+            if ($fileNodes -and $fileNodes.Count -gt 0) {
+                foreach ($fileNode in $fileNodes) {
+                    $absPath  = $fileNode.GetAttribute("path")
+                    $relPath  = $absPath -replace '^[A-Za-z]:[/\\]', ''
+                    $destPath = Join-Path $ScratchDir $relPath
+                    New-Item -Path (Split-Path $destPath -Parent) -ItemType Directory -Force -ErrorAction SilentlyContinue | Out-Null
+
+                    $ext = [IO.Path]::GetExtension($destPath).ToLower()
+                    $encoding = switch ($ext) {
+                        { $_ -in '.ps1', '.xml' }        { [System.Text.Encoding]::UTF8 }
+                        { $_ -in '.reg', '.vbs', '.js' } { [System.Text.UnicodeEncoding]::new($false, $true) }
+                        default                          { [System.Text.Encoding]::Default }
+                    }
+                    [System.IO.File]::WriteAllBytes($destPath, ($encoding.GetPreamble() + $encoding.GetBytes($fileNode.InnerText.Trim())))
+                    & $Log "Pre-staged setup script: $relPath"
+                }
+            } else {
+                & $Log "Warning: no <Extensions><File> nodes found in autounattend.xml — setup scripts not pre-staged."
+            }
+        } catch {
+            & $Log "Warning: could not pre-stage setup scripts from autounattend.xml: $_"
+        }
 
-        # ── Place autounattend.xml at the ISO / USB root ──────────────────────
-        # Windows Setup reads this file first (before booting into the OS),
-        # which is what drives the local-account / OOBE bypass at install time.
         if ($ISOContentsDir -and (Test-Path $ISOContentsDir)) {
             $isoDest = Join-Path $ISOContentsDir "autounattend.xml"
             Set-Content -Path $isoDest -Value $AutoUnattendXml -Encoding UTF8 -Force
@@ -272,8 +321,8 @@ function Invoke-WinUtilISOScript {
     Remove-ISOScriptReg 'HKLM\zSOFTWARE\Microsoft\WindowsUpdate\Orchestrator\UScheduler_Oobe\DevHomeUpdate'
 
     & $Log "Disabling Copilot..."
-    Set-ISOScriptReg 'HKLM\zSOFTWARE\Policies\Microsoft\Windows\WindowsCopilot' 'TurnOffWindowsCopilot'    'REG_DWORD' '1'
+    Set-ISOScriptReg 'HKLM\zSOFTWARE\Policies\Microsoft\Windows\WindowsCopilot' 'TurnOffWindowsCopilot'      'REG_DWORD' '1'
-    Set-ISOScriptReg 'HKLM\zSOFTWARE\Policies\Microsoft\Edge'                   'HubsSidebarEnabled'        'REG_DWORD' '0'
+    Set-ISOScriptReg 'HKLM\zSOFTWARE\Policies\Microsoft\Edge'                   'HubsSidebarEnabled'          'REG_DWORD' '0'
     Set-ISOScriptReg 'HKLM\zSOFTWARE\Policies\Microsoft\Windows\Explorer'       'DisableSearchBoxSuggestions' 'REG_DWORD' '1'
 
     & $Log "Disabling Windows Update during OOBE (re-enabled on first logon via FirstLogon.ps1)..."
@@ -304,12 +353,9 @@ function Invoke-WinUtilISOScript {
     reg unload HKLM\zSOFTWARE
     reg unload HKLM\zSYSTEM
 
-    # ═════════════════════════════════════════════════════════════════════════
+    # ── 5. Delete scheduled task definition files ─────────────────────────────
-    #  4. Delete scheduled task definition files
-    # ═════════════════════════════════════════════════════════════════════════
     & $Log "Deleting scheduled task definition files..."
     $tasksPath = "$ScratchDir\Windows\System32\Tasks"
-
     Remove-Item "$tasksPath\Microsoft\Windows\Application Experience\Microsoft Compatibility Appraiser" -Force -ErrorAction SilentlyContinue
     Remove-Item "$tasksPath\Microsoft\Windows\Customer Experience Improvement Program"                  -Recurse -Force -ErrorAction SilentlyContinue
     Remove-Item "$tasksPath\Microsoft\Windows\Application Experience\ProgramDataUpdater"               -Force -ErrorAction SilentlyContinue
@@ -321,12 +367,9 @@ function Invoke-WinUtilISOScript {
     Remove-Item "$tasksPath\Microsoft\Windows\WaaSMedic"                                               -Recurse -Force -ErrorAction SilentlyContinue
     Remove-Item "$tasksPath\Microsoft\Windows\WindowsUpdate"                                           -Recurse -Force -ErrorAction SilentlyContinue
     Remove-Item "$tasksPath\Microsoft\WindowsUpdate"                                                   -Recurse -Force -ErrorAction SilentlyContinue
-
     & $Log "Scheduled task files deleted."
 
-    # ═════════════════════════════════════════════════════════════════════════
+    # ── 6. Remove ISO support folder ─────────────────────────────────────────
-    #  5. Remove ISO support folder (fresh-install only; not needed)
-    # ═════════════════════════════════════════════════════════════════════════
     if ($ISOContentsDir -and (Test-Path $ISOContentsDir)) {
         & $Log "Removing ISO support\ folder..."
         Remove-Item -Path (Join-Path $ISOContentsDir "support") -Recurse -Force -ErrorAction SilentlyContinue

functions/private/Invoke-WinUtilISOUSB.ps1

@@ -0,0 +1,240 @@
+function Invoke-WinUtilISORefreshUSBDrives {
+    $combo    = $sync["WPFWin11ISOUSBDriveComboBox"]
+    $removable = @(Get-Disk | Where-Object { $_.BusType -eq "USB" } | Sort-Object Number)
+
+    $combo.Items.Clear()
+
+    if ($removable.Count -eq 0) {
+        $combo.Items.Add("No USB drives detected")
+        $combo.SelectedIndex = 0
+        $sync["Win11ISOUSBDisks"] = @()
+        Write-Win11ISOLog "No USB drives detected."
+        return
+    }
+
+    foreach ($disk in $removable) {
+        $sizeGB = [math]::Round($disk.Size / 1GB, 1)
+        $combo.Items.Add("Disk $($disk.Number): $($disk.FriendlyName)  [$sizeGB GB] - $($disk.PartitionStyle)")
+    }
+    $combo.SelectedIndex = 0
+    Write-Win11ISOLog "Found $($removable.Count) USB drive(s)."
+    $sync["Win11ISOUSBDisks"] = $removable
+}
+
+function Invoke-WinUtilISOWriteUSB {
+    $contentsDir = $sync["Win11ISOContentsDir"]
+    $usbDisks    = $sync["Win11ISOUSBDisks"]
+
+    if (-not $contentsDir -or -not (Test-Path $contentsDir)) {
+        [System.Windows.MessageBox]::Show("No modified ISO content found.  Please complete Steps 1-3 first.", "Not Ready", "OK", "Warning")
+        return
+    }
+
+    $combo = $sync["WPFWin11ISOUSBDriveComboBox"]
+    $selectedIndex = $combo.SelectedIndex
+    $selectedItemText = [string]$combo.SelectedItem
+    $usbDisks = @($usbDisks)
+
+    $targetDisk = $null
+    if ($selectedIndex -ge 0 -and $selectedIndex -lt $usbDisks.Count) {
+        $targetDisk = $usbDisks[$selectedIndex]
+    } elseif ($selectedItemText -match 'Disk\s+(\d+):') {
+        $selectedDiskNum = [int]$matches[1]
+        $targetDisk = $usbDisks | Where-Object { $_.Number -eq $selectedDiskNum } | Select-Object -First 1
+    }
+
+    if (-not $targetDisk) {
+        [System.Windows.MessageBox]::Show("Please select a USB drive from the dropdown.", "No Drive Selected", "OK", "Warning")
+        return
+    }
+
+    $diskNum    = $targetDisk.Number
+    $sizeGB     = [math]::Round($targetDisk.Size / 1GB, 1)
+
+    $confirm = [System.Windows.MessageBox]::Show(
+        "ALL data on Disk $diskNum ($($targetDisk.FriendlyName), $sizeGB GB) will be PERMANENTLY ERASED.`n`nAre you sure you want to continue?",
+        "Confirm USB Erase", "YesNo", "Warning")
+
+    if ($confirm -ne "Yes") {
+        Write-Win11ISOLog "USB write cancelled by user."
+        return
+    }
+
+    $sync["WPFWin11ISOWriteUSBButton"].IsEnabled = $false
+    Write-Win11ISOLog "Starting USB write to Disk $diskNum..."
+
+    $runspace = [Management.Automation.Runspaces.RunspaceFactory]::CreateRunspace()
+    $runspace.ApartmentState = "STA"
+    $runspace.ThreadOptions  = "ReuseThread"
+    $runspace.Open()
+    $runspace.SessionStateProxy.SetVariable("sync",        $sync)
+    $runspace.SessionStateProxy.SetVariable("diskNum",     $diskNum)
+    $runspace.SessionStateProxy.SetVariable("contentsDir", $contentsDir)
+
+    $script = [Management.Automation.PowerShell]::Create()
+    $script.Runspace = $runspace
+    $script.AddScript({
+
+        function Log($msg) {
+            $ts = (Get-Date).ToString("HH:mm:ss")
+            $sync["WPFWin11ISOStatusLog"].Dispatcher.Invoke([action]{
+                $sync["WPFWin11ISOStatusLog"].Text += "`n[$ts] $msg"
+                $sync["WPFWin11ISOStatusLog"].CaretIndex = $sync["WPFWin11ISOStatusLog"].Text.Length
+                $sync["WPFWin11ISOStatusLog"].ScrollToEnd()
+            })
+        }
+
+        function SetProgress($label, $pct) {
+            $sync["WPFWin11ISOStatusLog"].Dispatcher.Invoke([action]{
+                $sync.progressBarTextBlock.Text    = $label
+                $sync.progressBarTextBlock.ToolTip = $label
+                $sync.ProgressBar.Value            = [Math]::Max($pct, 5)
+            })
+        }
+
+        function Get-FreeDriveLetter {
+            $used = (Get-PSDrive -PSProvider FileSystem -ErrorAction SilentlyContinue).Name
+            foreach ($c in [char[]](68..90)) {
+                if ($used -notcontains [string]$c) { return $c }
+            }
+            return $null
+        }
+
+        try {
+            SetProgress "Formatting USB drive..." 10
+
+            # Phase 1: Clean disk via diskpart
+            $dpFile1 = Join-Path $env:TEMP "winutil_diskpart_$(Get-Random).txt"
+            "select disk $diskNum`nclean`nexit" | Set-Content -Path $dpFile1 -Encoding ASCII
+            Log "Running diskpart clean on Disk $diskNum..."
+            diskpart /s $dpFile1 2>&1 | Where-Object { $_ -match '\S' } | ForEach-Object { Log "  diskpart: $_" }
+            Remove-Item $dpFile1 -Force -ErrorAction SilentlyContinue
+
+            # Phase 2: Initialize as GPT
+            Start-Sleep -Seconds 2
+            Update-Disk -Number $diskNum -ErrorAction SilentlyContinue
+            $diskObj = Get-Disk -Number $diskNum -ErrorAction Stop
+            if ($diskObj.PartitionStyle -eq 'RAW') {
+                Initialize-Disk -Number $diskNum -PartitionStyle GPT -ErrorAction Stop
+                Log "Disk $diskNum initialized as GPT."
+            } else {
+                Set-Disk -Number $diskNum -PartitionStyle GPT -ErrorAction Stop
+                Log "Disk $diskNum converted to GPT (was $($diskObj.PartitionStyle))."
+            }
+
+            # Phase 3: Create FAT32 partition via diskpart
+            $volLabel = "W11-" + (Get-Date).ToString('yyMMdd')
+            $dpFile2  = Join-Path $env:TEMP "winutil_diskpart2_$(Get-Random).txt"
+            $maxFat32PartitionMB = 32768
+            $diskSizeMB = [int][Math]::Floor((Get-Disk -Number $diskNum -ErrorAction Stop).Size / 1MB)
+            $createPartitionCommand = "create partition primary"
+            if ($diskSizeMB -gt $maxFat32PartitionMB) {
+                $createPartitionCommand = "create partition primary size=$maxFat32PartitionMB"
+                Log "Disk $diskNum is $diskSizeMB MB; creating FAT32 partition capped at $maxFat32PartitionMB MB (32 GB)."
+            }
+
+            @(
+                "select disk $diskNum"
+                $createPartitionCommand
+                "format quick fs=fat32 label=`"$volLabel`""
+                "exit"
+            ) | Set-Content -Path $dpFile2 -Encoding ASCII
+            Log "Creating partitions on Disk $diskNum..."
+            diskpart /s $dpFile2 2>&1 | Where-Object { $_ -match '\S' } | ForEach-Object { Log "  diskpart: $_" }
+            Remove-Item $dpFile2 -Force -ErrorAction SilentlyContinue
+
+            SetProgress "Assigning drive letters..." 30
+            Start-Sleep -Seconds 3
+            Update-Disk -Number $diskNum -ErrorAction SilentlyContinue
+
+            $partitions = Get-Partition -DiskNumber $diskNum -ErrorAction Stop
+            Log "Partitions on Disk $diskNum after format: $($partitions.Count)"
+            foreach ($p in $partitions) {
+                Log "  Partition $($p.PartitionNumber)  Type=$($p.Type)  Letter=$($p.DriveLetter)  Size=$([math]::Round($p.Size/1MB))MB"
+            }
+
+            $winpePart = $partitions | Where-Object { $_.Type -eq "Basic" } | Select-Object -Last 1
+            if (-not $winpePart) {
+                throw "Could not find the WINPE (Basic) partition on Disk $diskNum after format."
+            }
+
+            try { Remove-PartitionAccessPath -DiskNumber $diskNum -PartitionNumber $winpePart.PartitionNumber -AccessPath "$($winpePart.DriveLetter):" -ErrorAction SilentlyContinue } catch {}
+            $usbLetter = Get-FreeDriveLetter
+            if (-not $usbLetter) { throw "No free drive letters (D-Z) available to assign to the USB data partition." }
+            Set-Partition -DiskNumber $diskNum -PartitionNumber $winpePart.PartitionNumber -NewDriveLetter $usbLetter
+            Log "Assigned drive letter $usbLetter to WINPE partition (Partition $($winpePart.PartitionNumber))."
+            Start-Sleep -Seconds 2
+
+            $usbDrive = "${usbLetter}:"
+            if (-not (Test-Path $usbDrive)) { throw "Drive $usbDrive is not accessible after letter assignment." }
+            Log "USB data partition: $usbDrive"
+
+            $contentSizeBytes = (Get-ChildItem -LiteralPath $contentsDir -File -Recurse -Force -ErrorAction Stop | Measure-Object -Property Length -Sum).Sum
+            if (-not $contentSizeBytes) { $contentSizeBytes = 0 }
+            $usbVolume = Get-Volume -DriveLetter $usbLetter -ErrorAction Stop
+            $partitionCapacityBytes = [int64]$usbVolume.Size
+            $partitionFreeBytes = [int64]$usbVolume.SizeRemaining
+
+            $contentSizeGB = [math]::Round($contentSizeBytes / 1GB, 2)
+            $partitionCapacityGB = [math]::Round($partitionCapacityBytes / 1GB, 2)
+            $partitionFreeGB = [math]::Round($partitionFreeBytes / 1GB, 2)
+
+            Log "Source content size: $contentSizeGB GB. USB partition capacity: $partitionCapacityGB GB, free: $partitionFreeGB GB."
+
+            if ($contentSizeBytes -gt $partitionCapacityBytes) {
+                throw "ISO content ($contentSizeGB GB) is larger than the USB partition capacity ($partitionCapacityGB GB). Use a larger USB drive or reduce image size."
+            }
+
+            if ($contentSizeBytes -gt $partitionFreeBytes) {
+                throw "Insufficient free space on USB partition. Required: $contentSizeGB GB, available: $partitionFreeGB GB."
+            }
+
+            SetProgress "Copying Windows 11 files to USB..." 45
+
+            # Copy files; split install.wim if > 4 GB (FAT32 limit)
+            $installWim = Join-Path $contentsDir "sources\install.wim"
+            if (Test-Path $installWim) {
+                $wimSizeMB = [math]::Round((Get-Item $installWim).Length / 1MB)
+                if ($wimSizeMB -gt 3800) {
+                    Log "install.wim is $wimSizeMB MB - splitting for FAT32 compatibility... This will take several minutes."
+                    $splitDest = Join-Path $usbDrive "sources\install.swm"
+                    New-Item -ItemType Directory -Path (Split-Path $splitDest) -Force | Out-Null
+                    Split-WindowsImage -ImagePath $installWim -SplitImagePath $splitDest -FileSize 3800 -CheckIntegrity
+                    Log "install.wim split complete."
+                    Log "Copying remaining files to USB..."
+                    & robocopy $contentsDir $usbDrive /E /XF install.wim /NFL /NDL /NJH /NJS
+                } else {
+                    & robocopy $contentsDir $usbDrive /E /NFL /NDL /NJH /NJS
+                }
+            } else {
+                & robocopy $contentsDir $usbDrive /E /NFL /NDL /NJH /NJS
+            }
+
+            SetProgress "Finalising USB drive..." 90
+            Log "Files copied to USB."
+            SetProgress "USB write complete" 100
+            Log "USB drive is ready for use."
+
+            $sync["WPFWin11ISOStatusLog"].Dispatcher.Invoke([action]{
+                [System.Windows.MessageBox]::Show(
+                    "USB drive created successfully!`n`nYou can now boot from this drive to install Windows 11.",
+                    "USB Ready", "OK", "Info")
+            })
+        } catch {
+            Log "ERROR during USB write: $_"
+            $sync["WPFWin11ISOStatusLog"].Dispatcher.Invoke([action]{
+                [System.Windows.MessageBox]::Show("USB write failed:`n`n$_", "USB Write Error", "OK", "Error")
+            })
+        } finally {
+            Start-Sleep -Milliseconds 800
+            $sync["WPFWin11ISOStatusLog"].Dispatcher.Invoke([action]{
+                $sync.progressBarTextBlock.Text    = ""
+                $sync.progressBarTextBlock.ToolTip = ""
+                $sync.ProgressBar.Value            = 0
+                $sync["WPFWin11ISOWriteUSBButton"].IsEnabled = $true
+            })
+        }
+    }) | Out-Null
+
+    $script.BeginInvoke() | Out-Null
+}

scripts/main.ps1

@@ -540,6 +540,10 @@ $sync["FontScalingApplyButton"].Add_Click({
 
 # ── Win11ISO Tab button handlers ──────────────────────────────────────────────
 
+$sync["WPFTab5BT"].Add_Click({
+    $sync["Form"].Dispatcher.BeginInvoke([System.Windows.Threading.DispatcherPriority]::Background, [action]{ Invoke-WinUtilISOCheckExistingWork }) | Out-Null
+})
+
 $sync["WPFWin11ISOBrowseButton"].Add_Click({
     Write-Debug "WPFWin11ISOBrowseButton clicked"
     Invoke-WinUtilISOBrowse

xaml/inputXML.xaml

@@ -273,22 +273,43 @@
         <Style TargetType="ComboBox">
             <Setter Property="Foreground" Value="{DynamicResource ComboBoxForegroundColor}" />
             <Setter Property="Background" Value="{DynamicResource ComboBoxBackgroundColor}" />
+            <Setter Property="MinWidth"   Value="{DynamicResource ButtonWidth}" />
             <Setter Property="Template">
                 <Setter.Value>
                     <ControlTemplate TargetType="ComboBox">
                         <Grid>
-                            <ToggleButton x:Name="ToggleButton"
+                            <Border x:Name="OuterBorder"
-                                          Background="{TemplateBinding Background}"
+                                    BorderBrush="{DynamicResource BorderColor}"
-                                          BorderBrush="{TemplateBinding Background}"
+                                    BorderThickness="1"
-                                          BorderThickness="0"
+                                    CornerRadius="{DynamicResource ButtonCornerRadius}"
-                                          IsChecked="{Binding IsDropDownOpen, Mode=TwoWay, RelativeSource={RelativeSource TemplatedParent}}"
+                                    Background="{TemplateBinding Background}">
-                                          ClickMode="Press">
+                                <ToggleButton x:Name="ToggleButton"
-                                <TextBlock Text="{TemplateBinding SelectionBoxItem}"
+                                              Background="Transparent"
-                                           Foreground="{TemplateBinding Foreground}"
+                                              BorderThickness="0"
-                                           Background="Transparent"
+                                              IsChecked="{Binding IsDropDownOpen, Mode=TwoWay, RelativeSource={RelativeSource TemplatedParent}}"
-                                           HorizontalAlignment="Center" VerticalAlignment="Center" Margin="2"
+                                              ClickMode="Press">
-                                           />
+                                    <Grid>
-                            </ToggleButton>
+                                        <Grid.ColumnDefinitions>
+                                            <ColumnDefinition Width="*"/>
+                                            <ColumnDefinition Width="Auto"/>
+                                        </Grid.ColumnDefinitions>
+                                        <TextBlock Grid.Column="0"
+                                                   Text="{TemplateBinding SelectionBoxItem}"
+                                                   Foreground="{TemplateBinding Foreground}"
+                                                   Background="Transparent"
+                                                   HorizontalAlignment="Left" VerticalAlignment="Center"
+                                                   Margin="6,3,2,3"/>
+                                        <Path Grid.Column="1"
+                                              Data="M 0,0 L 8,0 L 4,5 Z"
+                                              Fill="{TemplateBinding Foreground}"
+                                              Width="8" Height="5"
+                                              VerticalAlignment="Center"
+                                              HorizontalAlignment="Center"
+                                              Stretch="Uniform"
+                                              Margin="4,0,6,0"/>
+                                    </Grid>
+                                </ToggleButton>
+                            </Border>
                             <Popup x:Name="Popup"
                                    IsOpen="{TemplateBinding IsDropDownOpen}"
                                    Placement="Bottom"
@@ -297,11 +318,11 @@
                                    PopupAnimation="Slide">
                                 <Border x:Name="DropDownBorder"
                                         Background="{TemplateBinding Background}"
-                                        BorderBrush="{TemplateBinding Foreground}"
+                                        BorderBrush="{DynamicResource BorderColor}"
                                         BorderThickness="1"
                                         CornerRadius="4">
                                     <ScrollViewer>
-                                        <ItemsPresenter HorizontalAlignment="Center" VerticalAlignment="Center" Margin="2"/>
+                                        <ItemsPresenter HorizontalAlignment="Left" VerticalAlignment="Center" Margin="4,2"/>
                                     </ScrollViewer>
                                 </Border>
                             </Popup>
@@ -1340,21 +1361,17 @@
                 </ScrollViewer>
             </TabItem>
             <TabItem Header="Win11ISO" Visibility="Collapsed" Name="WPFTab5">
-                <ScrollViewer VerticalScrollBarVisibility="Auto" HorizontalScrollBarVisibility="Disabled" Margin="{DynamicResource TabContentMargin}">
+                <Grid Name="Win11ISOPanel" Margin="{DynamicResource TabContentMargin}" Background="Transparent">
-                    <Grid Background="Transparent" Name="Win11ISOPanel">
+                    <Grid.RowDefinitions>
-                        <Grid.RowDefinitions>
+                        <RowDefinition Height="Auto"/>  <!-- Steps 1-4 -->
-                            <RowDefinition Height="Auto"/>  <!-- Step 1: Select ISO -->
+                        <RowDefinition Height="*"/>     <!-- Log / Status -->
-                            <RowDefinition Height="Auto"/>  <!-- Step 2: Mount & Verify -->
+                    </Grid.RowDefinitions>
-                            <RowDefinition Height="Auto"/>  <!-- Step 3: Modify install.wim -->
-                            <RowDefinition Height="Auto"/>  <!-- Step 4: Output Options -->
-                            <RowDefinition Height="Auto"/>  <!-- Log / Status -->
-                        </Grid.RowDefinitions>
 
-                        <!-- ═══════════════════════════════════════════════════════════ -->
+                    <!-- Steps 1-4 -->
-                        <!-- STEP 1 : Select Windows 11 ISO                             -->
+                    <StackPanel Grid.Row="0">
-                        <!-- ═══════════════════════════════════════════════════════════ -->
+
-                        <Border Grid.Row="0" Name="WPFWin11ISOSelectSection" Style="{StaticResource BorderStyle}">
+                            <!-- ─── STEP 1 : Select Windows 11 ISO ─────────────── -->
-                            <Grid Margin="5">
+                            <Grid Name="WPFWin11ISOSelectSection" Margin="5" HorizontalAlignment="Left" MinWidth="{DynamicResource ButtonWidth}">
                                 <Grid.ColumnDefinitions>
                                     <ColumnDefinition Width="*"/>
                                     <ColumnDefinition Width="*"/>
@@ -1441,16 +1458,12 @@
                                     </StackPanel>
                                 </Border>
                             </Grid>
-                        </Border>
 
-                        <!-- ═══════════════════════════════════════════════════════════ -->
+                            <!-- ─── STEP 2 : Mount & Verify ISO ──────────────────── -->
-                        <!-- STEP 2 : Mount & Verify ISO                                -->
+                            <Grid Name="WPFWin11ISOMountSection"
-                        <!-- ═══════════════════════════════════════════════════════════ -->
+                                  Margin="5"
-                        <Border Grid.Row="1"
+                                  Visibility="Collapsed"
-                                Name="WPFWin11ISOMountSection"
+                                  HorizontalAlignment="Left" MinWidth="{DynamicResource ButtonWidth}">
-                                Style="{StaticResource BorderStyle}"
-                                Visibility="Collapsed">
-                            <Grid Margin="5">
                                 <Grid.ColumnDefinitions>
                                     <ColumnDefinition Width="Auto"/>
                                     <ColumnDefinition Width="*"/>
@@ -1472,6 +1485,13 @@
                                             HorizontalAlignment="Left"
                                             Width="Auto" Padding="12,0"
                                             Height="{DynamicResource ButtonHeight}"/>
+                                    <CheckBox Name="WPFWin11ISOInjectDrivers"
+                                              Content="Inject current system drivers"
+                                              FontSize="{DynamicResource FontSize}"
+                                              Foreground="{DynamicResource MainForegroundColor}"
+                                              IsChecked="False"
+                                              Margin="0,8,0,0"
+                                              ToolTip="Exports all drivers from this machine and injects them into install.wim and boot.wim. Recommended for systems with unsupported NVMe or network controllers."/>
                                 </StackPanel>
 
                                 <!-- Verification results panel -->
@@ -1500,22 +1520,17 @@
                                                   FontSize="{DynamicResource FontSize}"
                                                   Foreground="{DynamicResource MainForegroundColor}"
                                                   Background="{DynamicResource MainBackgroundColor}"
-                                                  BorderBrush="{DynamicResource BorderColor}"
+                                                  HorizontalAlignment="Left"
-                                                  HorizontalAlignment="Stretch"
                                                   Margin="0,0,0,0"/>
                                     </StackPanel>
                                 </Border>
                             </Grid>
-                        </Border>
 
-                        <!-- ═══════════════════════════════════════════════════════════ -->
+                            <!-- ─── STEP 3 : Modify install.wim ───────────────────── -->
-                        <!-- STEP 3 : Modify install.wim                                -->
+                            <StackPanel Name="WPFWin11ISOModifySection"
-                        <!-- ═══════════════════════════════════════════════════════════ -->
+                                        Margin="5"
-                        <Border Grid.Row="2"
+                                        Visibility="Collapsed"
-                                Name="WPFWin11ISOModifySection"
+                                        HorizontalAlignment="Left" MinWidth="{DynamicResource ButtonWidth}">
-                                Style="{StaticResource BorderStyle}"
-                                Visibility="Collapsed">
-                            <StackPanel Margin="5">
                                 <TextBlock FontSize="{DynamicResource FontSize}" FontWeight="Bold"
                                            Foreground="{DynamicResource MainForegroundColor}" Margin="0,0,0,8">
                                     Step 3 - Modify install.wim
@@ -1534,15 +1549,12 @@
                                         Width="Auto" Padding="12,0"
                                         Height="{DynamicResource ButtonHeight}"/>
                             </StackPanel>
-                        </Border>
 
-                        <!-- ═══════════════════════════════════════════════════════════ -->
+                            <!-- ─── STEP 4 : Output Options ───────────────────────── -->
-                        <!-- STEP 4 : Output Options                                    -->
+                            <StackPanel Name="WPFWin11ISOOutputSection"
-                        <!-- ═══════════════════════════════════════════════════════════ -->
+                                        Margin="5"
-                        <Border Grid.Row="3"
+                                        Visibility="Collapsed"
-                                Name="WPFWin11ISOOutputSection"
+                                        HorizontalAlignment="Left" MinWidth="{DynamicResource ButtonWidth}">
-                                Style="{StaticResource BorderStyle}">
-                            <StackPanel Margin="5">
                                 <!-- Header row: title + Clean & Reset button -->
                                 <Grid Margin="0,0,0,12">
                                     <Grid.ColumnDefinitions>
@@ -1579,7 +1591,7 @@
                                             Height="{DynamicResource ButtonHeight}"/>
                                     <Button Grid.Column="2"
                                             Name="WPFWin11ISOChooseUSBButton"
-                                            Content="Write Directly to a USB Drive  (erases drive)"
+                                            Content="Write Directly to a USB Drive (ERASES DRIVE)"
                                             Foreground="OrangeRed"
                                             HorizontalAlignment="Stretch"
                                             Width="Auto" Padding="12,0"
@@ -1613,7 +1625,7 @@
                                                       Margin="0,0,6,0"/>
                                             <Button Grid.Column="1"
                                                     Name="WPFWin11ISORefreshUSBButton"
-                                                    Content="↻ Refresh"
+                                                    Content="Refresh"
                                                     Width="Auto" Padding="8,0"
                                                     Height="{DynamicResource ButtonHeight}"/>
                                         </Grid>
@@ -1626,34 +1638,37 @@
                                                 Margin="0,0,0,10"/>
                                     </StackPanel>
                                 </Border>
-
                             </StackPanel>
-                        </Border>
 
-                        <!-- ═══════════════════════════════════════════════════════════ -->
+                    </StackPanel>
-                        <!-- Status / Log Output                                        -->
-                        <!-- ═══════════════════════════════════════════════════════════ -->
-                        <Border Grid.Row="4" Style="{StaticResource BorderStyle}">
-                            <StackPanel>
-                                <TextBlock FontSize="{DynamicResource FontSize}" FontWeight="Bold"
-                                           Foreground="{DynamicResource MainForegroundColor}" Margin="0,0,0,6">
-                                    Status Log
-                                </TextBlock>
-                                <TextBox Name="WPFWin11ISOStatusLog"
-                                         IsReadOnly="True"
-                                         TextWrapping="Wrap"
-                                         VerticalScrollBarVisibility="Auto"
-                                         Height="140" Padding="6"
-                                         Background="{DynamicResource MainBackgroundColor}"
-                                         Foreground="{DynamicResource MainForegroundColor}"
-                                         BorderBrush="{DynamicResource BorderColor}"
-                                         BorderThickness="1"
-                                         Text="Ready. Please select a Windows 11 ISO to begin."/>
-                            </StackPanel>
-                        </Border>
 
+                    <!-- Status Log (fills remaining height) -->
+                    <Grid Grid.Row="1" Margin="5">
+                        <Grid.RowDefinitions>
+                            <RowDefinition Height="Auto"/>
+                            <RowDefinition Height="*"/>
+                        </Grid.RowDefinitions>
+                        <TextBlock Grid.Row="0"
+                                   FontSize="{DynamicResource FontSize}" FontWeight="Bold"
+                                   Foreground="{DynamicResource MainForegroundColor}"
+                                   Margin="0,0,0,4">
+                            Status Log
+                        </TextBlock>
+                        <TextBox Grid.Row="1"
+                                 Name="WPFWin11ISOStatusLog"
+                                 IsReadOnly="True"
+                                 TextWrapping="Wrap"
+                                 VerticalScrollBarVisibility="Visible"
+                                 VerticalAlignment="Stretch"
+                                 Padding="6"
+                                 Background="{DynamicResource MainBackgroundColor}"
+                                 Foreground="{DynamicResource MainForegroundColor}"
+                                 BorderBrush="{DynamicResource BorderColor}"
+                                 BorderThickness="1"
+                                 Text="Ready. Please select a Windows 11 ISO to begin."/>
                     </Grid>
-                </ScrollViewer>
+
+                </Grid>
             </TabItem>
         </TabControl>
     </Grid>