Getting your OS Restore DVD to work with large image files

This week, we completed the Windows 7 x64 build for our internal Tech Community. During the testing of the OS Restore DVD we ran into a problem when attempting to restore the image from DVD.

Our custom Windows 7 64 bit image has a size of approx. 4.8 GB. This because the 64 bit version of Windows7 has a larger footprint than the 32 bit version and because we had included some applications like Office 2010 CTP and some drivers for a limited number of hardware. Since we did not want to split the content across multiple DVD’s, we had decided that we would create just one ISO with OSCDIMG.EXE life that people would need to burn on a Dual Layer DVD which provides enough capacity.

Oscdimg is a command-line tool for creating an image file (.iso) of a customized 32-bit or 64-bit version of Windows PE. You can then burn that .iso file to a CD-ROM or DVD-ROM. The OSCDIMG.EXE is provided with the Windows Automated Installation Toolkit (WAIK).

The problem we faced was that once WinPE was booted and the image restore process was started, Image.exe terminated with an error message. We had used the exact same process to produce restore DVD for the 64 bit OS as we used about thousand times before for the 32 bit version. Our first thought was that something had probably gone wrong when burning the DVD, but before wasting another DL-DVD that are quite expensive, we tested the ISO file within a virtual machine, and…. got the same error.

When we checked the image file (win7x64.wim) on the DVD we noticed that the displayed file size was listed as less than a megabyte, the image file we had added to the DVD had approx 4.8 GB.

After some searching we found out that the problem had to do with the large image file and the DVD that was created with the Joliet File System.


To get our Restore DVD to work with a large image file, we used the –u2 command line option with OSCDIMG.EXE. Using the –u2 option instructs Oscdimg to use the UDF file system.

Thanks to Ted for finding this out.

The below relates to Windows XP and UDF, but might be useful to know as well.

DVD-RW disks appear to be empty in Windows Explorer on a Windows XP Service Pack 2-based computer

CD-ROM Drive May Not Be Able to Read a UDF-Formatted Disc in Windows XP

4 Replies to “Getting your OS Restore DVD to work with large image files”

  1. Alex,
    I wanted to say thank you and Ted for this article…it is the only one of it’s kind and helped me to resolve the exact same issue you were facing.
    We normally use a Custom WinPE Boot to deploy images from our ghost consoles but we had a need to have a standalone bootable CD to deploy our Ghost Image. I was creating the WinPE ISO using oscdimg -n -m method and the result was a bootable DVD that would start Ghost and then begin restore of the GHO image to about 6% and then fail with an “Error 1008: Unexpected End of File”. My research and KB articles search lead me to believe the cause and solution involved filename syntax, etc. This was definitely not the case after I had burned and tested about 20 DVD’s to prove as much.
    Then I ran across your article and rebuilt the ISO using “oscdimg -m -u2….” then burned using Nero Burning Rom. The first boot failed. I later discoverd I had to set Nero to burn at 2.4x in order for it to correctly burn the ISO. This might be worth a mention in your article.
    Again, I truly appreciate this article…I wish I had found it before I had alredy wasted several days and DVD attempting to resolve by the other solutions posted.

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