There's probably a pre-made stick for this already but I don't know where it is. Here's the low level overview - I don't know how to run it under Windows though:<BR><BR>The trick is to use syslinux on ...

So today I got an idea. Some box somewhere has a disk problem so I did an offline dd_rescue disk copy to a healthy drive on site. I booted from knoppix USB drive and started the dd and walked out.