be doing wrong? ttp://www.hightechdad.com hightechdad I ran into that issue once before. I had to recreate the DMG and run the repair disk to make it bootable as well. Be sure that you select the right partition type (GUID one). Or you could read down in the comments where Benoit listed an additional flag. Try going through it again and watch for those errors. Jon Very strange! Still not working here. On my InstallESD.dmg I show it as having a capacity of 4.75 GB, with 4.38 GB used. When I make a single-layer disk image to copy to, I see a capacity of 4.36 GB with 4.33 GB available. What could I be missing? Thanks for any help! ttp://www.hightechdad.com hightechdad So, when you did the cp, you had both the InstallESD.dmg mounted (which I did by double clicking within Disk Utility) and the new DMG (with the proper partition and GUID and you ran Repair disk on that and it mounted successfully?)? When you created the DMG, you did choose the DVD size, right? Post a screenshot if you want. dto458 I'm having the same problem as Jon, I did do all the steps correctly. Here is the Terminal. What's strange is even after selecting 4.6Gb it shows the partition as 4.3. I posted the image of the partition. ttp://www.hightechdad.com hightechdad I didn't see a screenshot. But I was able to get it to work. Perhaps if you posted (or wrote down) each step that you do, then you might