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Author SHA1 Message Date
Chris Titus
410d3c5056 initial usb fixes 2026-02-25 10:44:33 -06:00
5 changed files with 280 additions and 199 deletions

View File

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

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@@ -446,6 +446,53 @@ function Invoke-WinUtilISOModify {
$script.BeginInvoke() | Out-Null
}
function Invoke-WinUtilISOCheckExistingWork {
<#
.SYNOPSIS
Called when the Win11ISO tab is opened. Checks for a pre-existing
WinUtil_Win11ISO temp directory and, if found, restores the working-
directory state so the user can proceed directly to Step 4 (output
options) without repeating the modification.
#>
# If state is already loaded (e.g. user just switched tabs mid-session)
# do nothing so we don't overwrite in-progress work.
if ($sync["Win11ISOContentsDir"] -and (Test-Path $sync["Win11ISOContentsDir"])) {
return
}
$existingWorkDir = Get-Item -Path (Join-Path $env:TEMP "WinUtil_Win11ISO*") -ErrorAction SilentlyContinue |
Where-Object { $_.PSIsContainer } |
Sort-Object LastWriteTime -Descending |
Select-Object -First 1
if (-not $existingWorkDir) { return }
$isoContents = Join-Path $existingWorkDir.FullName "iso_contents"
if (-not (Test-Path $isoContents)) { return }
# Restore state
$sync["Win11ISOWorkDir"] = $existingWorkDir.FullName
$sync["Win11ISOContentsDir"] = $isoContents
# Show Step 4 and collapse steps 1-3 (modification already happened)
$sync["WPFWin11ISOSelectSection"].Visibility = "Collapsed"
$sync["WPFWin11ISOMountSection"].Visibility = "Collapsed"
$sync["WPFWin11ISOModifySection"].Visibility = "Collapsed"
$sync["WPFWin11ISOOutputSection"].Visibility = "Visible"
# Notify via the status log
$dirName = $existingWorkDir.Name
$modified = $existingWorkDir.LastWriteTime.ToString("yyyy-MM-dd HH:mm")
Write-Win11ISOLog "Existing working directory found: $($existingWorkDir.FullName)"
Write-Win11ISOLog "Last modified: $modified — Skipping Steps 1-3 and resuming at Step 4."
Write-Win11ISOLog "Click 'Clean & Reset' if you want to start over with a new ISO."
[System.Windows.MessageBox]::Show(
"A previous WinUtil ISO working directory was found:`n`n$($existingWorkDir.FullName)`n`n(Last modified: $modified)`n`nStep 4 (output options) has been restored so you can save the already-modified image.`n`nClick 'Clean & Reset' in Step 4 if you want to start over.",
"Existing Work Found", "OK", "Info")
}
function Invoke-WinUtilISOCleanAndReset {
<#
.SYNOPSIS
@@ -600,7 +647,7 @@ function Invoke-WinUtilISOExport {
}
if ($proc.ExitCode -eq 0) {
Set-WinUtilProgressBar -Label "ISO exported" -Percent 100
Set-WinUtilProgressBar -Label "ISO exported" -Percent 100
Write-Win11ISOLog "ISO exported successfully: $outputISO"
[System.Windows.MessageBox]::Show(
"ISO exported successfully!`n`n$outputISO",
@@ -622,197 +669,3 @@ function Invoke-WinUtilISOExport {
}
}
function Invoke-WinUtilISORefreshUSBDrives {
<#
.SYNOPSIS
Populates the USB drive ComboBox with all currently attached removable drives.
#>
$combo = $sync["WPFWin11ISOUSBDriveComboBox"]
$combo.Items.Clear()
$removable = Get-Disk | Where-Object { $_.BusType -eq "USB" } | Sort-Object Number
if ($removable.Count -eq 0) {
$combo.Items.Add("No USB drives detected")
$combo.SelectedIndex = 0
Write-Win11ISOLog "No USB drives detected."
return
}
foreach ($disk in $removable) {
$sizeGB = [math]::Round($disk.Size / 1GB, 1)
$label = "Disk $($disk.Number): $($disk.FriendlyName) [$sizeGB GB] — $($disk.PartitionStyle)"
$combo.Items.Add($label)
}
$combo.SelectedIndex = 0
Write-Win11ISOLog "Found $($removable.Count) USB drive(s)."
# Store disk objects for later use
$sync["Win11ISOUSBDisks"] = $removable
}
function Invoke-WinUtilISOWriteUSB {
<#
.SYNOPSIS
Erases the selected USB drive and writes the modified Windows 11 ISO
content as a bootable installation drive (using DISM / robocopy approach).
#>
$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 13 first.",
"Not Ready", "OK", "Warning")
return
}
$selectedIndex = $sync["WPFWin11ISOUSBDriveComboBox"].SelectedIndex
if ($selectedIndex -lt 0 -or -not $usbDisks -or $selectedIndex -ge $usbDisks.Count) {
[System.Windows.MessageBox]::Show(
"Please select a USB drive from the dropdown.",
"No Drive Selected", "OK", "Warning")
return
}
$targetDisk = $usbDisks[$selectedIndex]
$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)
})
}
try {
SetProgress "Formatting USB drive..." 10
# ── Diskpart script: clean, GPT, create ESP + data partitions ──
$dpScript = @"
select disk $diskNum
clean
convert gpt
create partition efi size=512
format quick fs=fat32 label="SYSTEM"
assign
create partition primary
format quick fs=fat32 label="WINPE"
assign
exit
"@
$dpFile = Join-Path $env:TEMP "winutil_diskpart_$(Get-Random).txt"
$dpScript | Set-Content -Path $dpFile -Encoding ASCII
Log "Running diskpart on Disk $diskNum..."
diskpart /s $dpFile | Out-Null
Remove-Item $dpFile -Force
SetProgress "Identifying USB partitions..." 30
Start-Sleep -Seconds 3 # let Windows assign drive letters
# Find newly assigned drive letter for the data partition
$usbVol = Get-Partition -DiskNumber $diskNum |
Where-Object { $_.Type -eq "Basic" } |
Get-Volume |
Where-Object { $_.FileSystemLabel -eq "WINPE" } |
Select-Object -First 1
if (-not $usbVol) {
throw "Could not locate the formatted USB data partition. Drive letter may not have been assigned automatically."
}
$usbDrive = "$($usbVol.DriveLetter):"
Log "USB data partition: $usbDrive"
SetProgress "Copying Windows 11 files to USB..." 45
# ── Copy files (split large install.wim if > 4 GB for FAT32) ──
$installWim = Join-Path $contentsDir "sources\install.wim"
if (Test-Path $installWim) {
$wimSizeMB = [math]::Round((Get-Item $installWim).Length / 1MB)
if ($wimSizeMB -gt 3800) {
# FAT32 limit split with DISM
Log "install.wim is $wimSizeMB MB splitting for FAT32 compatibility..."
$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 | Out-Null
Log "install.wim split complete."
# Copy everything else (exclude install.wim)
$robocopyArgs = @($contentsDir, $usbDrive, "/E", "/XF", "install.wim", "/NFL", "/NDL", "/NJH", "/NJS")
& robocopy @robocopyArgs | Out-Null
} else {
& robocopy $contentsDir $usbDrive /E /NFL /NDL /NJH /NJS | Out-Null
}
} else {
& robocopy $contentsDir $usbDrive /E /NFL /NDL /NJH /NJS | Out-Null
}
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
}

View File

@@ -0,0 +1,222 @@
function Invoke-WinUtilISORefreshUSBDrives {
<#
.SYNOPSIS
Populates the USB drive ComboBox with all currently attached removable drives.
#>
$combo = $sync["WPFWin11ISOUSBDriveComboBox"]
$combo.Items.Clear()
$removable = Get-Disk | Where-Object { $_.BusType -eq "USB" } | Sort-Object Number
if ($removable.Count -eq 0) {
$combo.Items.Add("No USB drives detected")
$combo.SelectedIndex = 0
Write-Win11ISOLog "No USB drives detected."
return
}
foreach ($disk in $removable) {
$sizeGB = [math]::Round($disk.Size / 1GB, 1)
$label = "Disk $($disk.Number): $($disk.FriendlyName) [$sizeGB GB] — $($disk.PartitionStyle)"
$combo.Items.Add($label)
}
$combo.SelectedIndex = 0
Write-Win11ISOLog "Found $($removable.Count) USB drive(s)."
# Store disk objects for later use
$sync["Win11ISOUSBDisks"] = $removable
}
function Invoke-WinUtilISOWriteUSB {
<#
.SYNOPSIS
Erases the selected USB drive and writes the modified Windows 11 ISO
content as a bootable installation drive (using DISM / robocopy approach).
#>
$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 13 first.",
"Not Ready", "OK", "Warning")
return
}
$selectedIndex = $sync["WPFWin11ISOUSBDriveComboBox"].SelectedIndex
if ($selectedIndex -lt 0 -or -not $usbDisks -or $selectedIndex -ge $usbDisks.Count) {
[System.Windows.MessageBox]::Show(
"Please select a USB drive from the dropdown.",
"No Drive Selected", "OK", "Warning")
return
}
$targetDisk = $usbDisks[$selectedIndex]
$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)
})
}
try {
SetProgress "Formatting USB drive..." 10
# ── Helper: find a free drive letter (D-Z) ──────────────────────────
function Get-FreeDriveLetter {
$used = (Get-PSDrive -PSProvider FileSystem -ErrorAction SilentlyContinue).Name
foreach ($c in [char[]](68..90)) { # D..Z
if ($used -notcontains [string]$c) { return $c }
}
return $null
}
# ── Diskpart script: clean + GPT + format only (no assign) ──────────
# We intentionally omit "assign" here and let PowerShell assign letters
# explicitly below. diskpart's "assign" can silently fail on drives that
# previously had letter bindings still present in the registry, which is
# the root cause of the "could not locate partition" error.
$dpScript = @"
select disk $diskNum
clean
convert gpt
create partition efi size=512
format quick fs=fat32 label="SYSTEM"
create partition primary
format quick fs=fat32 label="WINPE"
exit
"@
$dpFile = Join-Path $env:TEMP "winutil_diskpart_$(Get-Random).txt"
$dpScript | Set-Content -Path $dpFile -Encoding ASCII
Log "Running diskpart on Disk $diskNum..."
$dpOut = diskpart /s $dpFile 2>&1
Remove-Item $dpFile -Force -ErrorAction SilentlyContinue
# Log diskpart output for diagnostics
$dpOut | Where-Object { $_ -match '\S' } | ForEach-Object { Log " diskpart: $_" }
SetProgress "Assigning drive letters..." 30
Start-Sleep -Seconds 3 # allow Windows to settle after partition creation
Update-Disk -Number $diskNum -ErrorAction SilentlyContinue
# ── Explicitly assign drive letters via PowerShell ───────────────────
# This is reliable regardless of registry state, unlike diskpart assign.
$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."
}
# Remove stale letter first (noops if none), then assign a fresh one
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"
SetProgress "Copying Windows 11 files to USB..." 45
# ── Copy files (split large install.wim if > 4 GB for FAT32) ──
$installWim = Join-Path $contentsDir "sources\install.wim"
if (Test-Path $installWim) {
$wimSizeMB = [math]::Round((Get-Item $installWim).Length / 1MB)
if ($wimSizeMB -gt 3800) {
# FAT32 limit split with DISM
Log "install.wim is $wimSizeMB MB splitting for FAT32 compatibility..."
$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 | Out-Null
Log "install.wim split complete."
# Copy everything else (exclude install.wim)
$robocopyArgs = @($contentsDir, $usbDrive, "/E", "/XF", "install.wim", "/NFL", "/NDL", "/NJH", "/NJS")
& robocopy @robocopyArgs | Out-Null
} else {
& robocopy $contentsDir $usbDrive /E /NFL /NDL /NJH /NJS | Out-Null
}
} else {
& robocopy $contentsDir $usbDrive /E /NFL /NDL /NJH /NJS | Out-Null
}
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
}

View File

@@ -534,6 +534,11 @@ $sync["FontScalingApplyButton"].Add_Click({
# ── Win11ISO Tab button handlers ──────────────────────────────────────────────
# Check for an existing working directory each time the Win11ISO tab is opened
$sync["WPFTab5BT"].Add_Click({
Invoke-WinUtilISOCheckExistingWork
})
$sync["WPFWin11ISOBrowseButton"].Add_Click({
Write-Debug "WPFWin11ISOBrowseButton clicked"
Invoke-WinUtilISOBrowse

View File

@@ -1541,7 +1541,8 @@
<!-- ═══════════════════════════════════════════════════════════ -->
<Border Grid.Row="3"
Name="WPFWin11ISOOutputSection"
Style="{StaticResource BorderStyle}">
Style="{StaticResource BorderStyle}"
Visibility="Collapsed">
<StackPanel Margin="5">
<!-- Header row: title + Clean & Reset button -->
<Grid Margin="0,0,0,12">
@@ -1579,7 +1580,7 @@
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 +1614,7 @@
Margin="0,0,6,0"/>
<Button Grid.Column="1"
Name="WPFWin11ISORefreshUSBButton"
Content="Refresh"
Content="Refresh"
Width="Auto" Padding="8,0"
Height="{DynamicResource ButtonHeight}"/>
</Grid>