The FreeDOS files I supply in the zip file for download do NOT support FAT32. If you have a key larger than 2GB, you will need a Fat32 compatible set of system files.

Disclaimer: This software is written and distributed by HP (Hewlett Packard). I have just zipped everything up and included additional boot files so that it makes the process easier, I did not write or modify this application in any way.

Create a directory in "My Documents", in this example I named it "Drivekey", but you may name the directory anything you like, just remember its name and where it is.
Download and save this file in that directory: Link to Zip File
Once that is done, unzip it, insert the USB key you want to work with, and execute the "RunThis" file.
I have included bootfiles that just boot to a basic FreeDOS partition so that you have easy access for flashing bios files, etc.

You will now see this, If you have more than 1 USB device, make sure you choose the correct one as shown here (of course names may vary, this is just what my PC showed):



Now pick your file system (FAT is ok for 1 and 2GB keys, FAT32 must be used for keys larger than 2GB):



Now pick the name of the device:



Now since you want to make it bootable, you need to tell it to "create MS-DOS Startup disk":



Now click the box to the right, so you can browse folders:



Now navigate to the folder that you unzipped this into and find the "bootfiles" folder:
Note: Your window will not look like this, unless you named the folder "Drivekey".




Now click start:



When its all done, you will get the summary screen looking like this:



You should now be able to plug the USB key in, turn on your PC and select it as a boot device.
Once completed, the drive will be blank, so if you need it bootable to flash a bios, or run some other utilities outside of Windows, you will need to put those files on the drive. This only makes the key bootable, it does not put any utilities (fdisk, etc) on the drive.
The PC should boot with a quick flash of the Windows 98 splash screen and leave you at a C: prompt.