How to Create a Bootable Windows 7 Installation USB Flash Drive

1. Plug the USB key in.

2. If AutoPlay opens a pop-up for the USB key, then just close it.
NOTE: Make note of what the drive size is for the USB key for step 6 below. You can also open Computer (step 21) to see what the drive size is to. For example, mine is 3920 MB. (See screenshot below)
USB Windows 7 Installation Key Drive - Create-computer.jpg
3. Open a elevated command prompt.

4. In the elevated command prompt, type diskpart and press Enter. (See screenshot below)
USB Windows 7 Installation Key Drive - Create-step1.jpg
5. In the elevated command prompt, type list disk and press Enter. (See screenshot below)
NOTE: Make note of what disk # your USB key is listed as for step 6 below. You can also look for the drive size (step 2) for the USB key to help ID the disk number. For example, mine is listed as Disk 1 here for the 3920 MB disk.
USB Windows 7 Installation Key Drive - Create-step2.jpg
6. In the elevated command prompt, type select disk # (your USB disk #) and press Enter. (See screenshot below)
NOTE: You can also look for the drive size (step 2) for the USB key to help ID the disk number. For example, my USB key is listed as Disk 1, so I would type select disk 1 and press Enter.
USB Windows 7 Installation Key Drive - Create-step3.jpg
7. In the elevated command prompt, type clean and press Enter. (See screenshot below)
USB Windows 7 Installation Key Drive - Create-step4.jpg
8. In the elevated command prompt, type create partition primary and press Enter. (See screenshot below)
USB Windows 7 Installation Key Drive - Create-step5.jpg
9. In the elevated command prompt, type select partition 1 and press Enter. (See screenshot below)
USB Windows 7 Installation Key Drive - Create-step6.jpg
10. In the elevated command prompt, type active and press Enter. (See screenshot below)
USB Windows 7 Installation Key Drive - Create-step7.jpg
11. In the elevated command prompt, type format fs=ntfs quick OR format fs=fat32 quick and press Enter. (See screenshot below)
NOTE: This may take a few moments to finish formatting the USB key.
USB Windows 7 Installation Key Drive - Create-step8.jpg
12. If AutoPlay opens a pop-up for the USB key, then just close it.

13. In the elevated command prompt, type assign and press Enter. (See screenshot below)
NOTE: This will assign a new drive letter to the USB key. Make note of the new USB drive letter for step 19 below. For example, mine is now H.
USB Windows 7 Installation Key Drive - Create-step9.jpg
14. If AutoPlay opens a pop-up for the USB key, then just close it.
NOTE: Make note of the new USB drive letter for step 19 below. For example, mine is now H.

15. In the elevated command prompt, type exit and press Enter. (See screenshot below)
NOTE: This will exit you from DiskPart from step 4.
USB Windows 7 Installation Key Drive - Create-step10.jpg
16. Close the elevated command prompt.

17. Insert your Windows 7 installation DVD into the DVD drive.

18. If AutoPlay opens a pop-up for the Windows 7 installation DVD, then just close it.
NOTE: Make note of what the drive letter is for the DVD drive that has the Windows 7 installation DVD in for step 18 below. You can also open Computer (step 21) to see what the drive letter is to. (See right screenshot below)

19. Open the Start Menu, and right click on the Computer button and click on Open.

20. Right click on the DVD drive (ex: E: ) that has the Windows 7 installation DVD, and click on Open. (See screenshot below)
USB Windows 7 Installation Key Drive - Create-open.jpg
21. Highlight all of the contents, right click on the highlighted contents, and click on Copy. (See screenshot below)
NOTE: You will need to copy all of the files and folders on the Windows 7 installation DVD to the USB key.
USB Windows 7 Installation Key Drive - Create-copy.jpg
22. Go back to Computer, right click on the USB key drive (ex: H ), and click on Paste. (See screenshot below)
USB Windows 7 Installation Key Drive - Create-paste.jpg
23. The contents of the Windows 7 installation DVD will now start copying over to the USB key. (See screenshot below)
NOTE: This may take a few moments to complete.
USB Windows 7 Installation Key Drive - Create-copying.jpg
24. When finished, you can close the Computer window and unplug the USB key.

25. You now have a Windows 7 Installation USB key.

article source:http://www.sevenforums.com/tutorials/2432-usb-windows-7-installation-key-drive-create.html