Further to what I said I've just made a 64Mb grml2usb
dd if=/dev/zero of=/dev/sdb bs=512 count=2880 cfdisk /dev/sdb ## made the whole disk a single type 06 (fat16) partition mount /dev/sdb1 /mnt/sdb1 grml2usb grml_small.iso /dev/sdb1
And now
# fdisk -l /dev/sdb
Disk /dev/sdb: 66 MB, 66882048 bytes 3 heads, 43 sectors/track, 1012 cylinders Units = cylinders of 129 * 512 = 66048 bytes Disk identifier: 0x00000000
Device Boot Start End Blocks Id System /dev/sdb1 1 1012 65252+ 6 FAT16
# fdisk -l -u /dev/sdb
Disk /dev/sdb: 66 MB, 66882048 bytes 3 heads, 43 sectors/track, 1012 cylinders, total 130629 sectors Units = sectors of 1 * 512 = 512 bytes Disk identifier: 0x00000000
Device Boot Start End Blocks Id System /dev/sdb1 43 130547 65252+ 6 FAT16
So I've got a peculiar 43 sectors per track instead of the usual 63. But I've no way of testing if it boots or not.
Best Wishes Moss