I am trying to create a USB install stick which will contain some extra files to copy care of the ks.cfg.

But I run into 2 problems, depending on which help guide I follow!

1a. Copy USB diskboot
As stated on the RHEL-5 Installation Guide ch02s04s01, the following code should do the trick :-
Code:
dd if=diskboot.img of=/dev/sda
And yes, it does actually work/boot, but it obliterates the MBR!

Code:
# fdisk -l

Disk /dev/hdc: 4096 MB, 4096253952 bytes
255 heads, 63 sectors/track, 498 cylinders
Units = cylinders of 16065 * 512 = 8225280 bytes

   Device Boot      Start         End      Blocks   Id  System
/dev/hdc1   *           1         498     4000153+  83  Linux

Disk /dev/sda: 4009 MB, 4009754624 bytes
124 heads, 62 sectors/track, 1018 cylinders
Units = cylinders of 7688 * 512 = 3936256 bytes

This doesn't look like a partition table
Probably you selected the wrong device.

   Device Boot      Start         End      Blocks   Id  System
/dev/sda1   ?      392888      392954      253319   e4  SpeedStor
Partition 1 has different physical/logical beginnings (non-Linux?):
     phys=(190, 120, 0) logical=(392887, 53, 51)
Partition 1 has different physical/logical endings:
     phys=(544, 125, 44) logical=(392953, 41, 24)
Partition 1 does not end on cylinder boundary.
/dev/sda2   ?      130927      389508   993984023   98  Unknown
Partition 2 has different physical/logical beginnings (non-Linux?):
     phys=(1010, 16, 43) logical=(130926, 48, 10)
Partition 2 has different physical/logical endings:
     phys=(205, 205, 22) logical=(389507, 4, 55)
Partition 2 does not end on cylinder boundary.
/dev/sda3   ?      220685      470413   959953209   7d  Unknown
Partition 3 has different physical/logical beginnings (non-Linux?):
     phys=(252, 139, 46) logical=(220684, 115, 54)
Partition 3 has different physical/logical endings:
     phys=(367, 195, 2) logical=(470412, 76, 25)
Partition 3 does not end on cylinder boundary.
/dev/sda4   ?         691        1774     4161536    0  Empty
Partition 4 has different physical/logical beginnings (non-Linux?):
     phys=(0, 10, 0) logical=(690, 59, 39)
Partition 4 has different physical/logical endings:
     phys=(0, 0, 0) logical=(1773, 10, 44)
Partition 4 does not end on cylinder boundary.

Partition table entries are not in disk order
Surely the command should be?? (i.e. give it a partition number?)
Code:
dd if=diskboot.img of=/dev/sda1

In anycase, this gives me a 12Mb partition that about 30% is used.
So I cant fit a lot in there!


1b. Create own image file, but Larger!
I can do that, and again it boots, but it then brings me to my second problem



2. Do it the long (prober) way
I read these steps, and the like around places :-
1. make 2 partition of usb drive, first 500mb and another more then 3gb
2. In first partition install bootable image (diskboot.img)
3. In second partition (sdb2) copy ISO image of RHEL 5
4. first step will take you up to install from
5. cdrom/harddrive/nfs/ftp/http srceen. select harddisk, sdb2 and follow the steps to complete you installation

>2. as above.
>3. Does that mean the files or the ISO as a file?
>5. I cannot get to choose the sda1/2!?

Code:
Installation Method 
What type of media contains the  packages to be installed? 
Select : Hard drive 

Select Partition - 
What partition and directory on that partition hold the CD (iso9660) images for Red Hat Enterprise Linux Server? 
If you don't see the disk drive you're using listed here, press F2 to configure additional devices.  
  dev/hdc1
Directory holding images: ______________

Select:F2


Driver Disk Source
You have multiple devices which could serve as sources for a driver disk. Which would you like to use?
hdc
sda

Select:sda


Insert Driver Disk 
Insert your driver disk into /dev/sda  and press "OK" to continue.


Error - Driver disk is invalid for this release of Red Hat Enterprise Linux Server.