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Rescue USB storage - Size Limit

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I'm using Acronis True Image 2016, and I would like to create a recovery USB disk.

I prefer to also put the image files into the bootable disk, so I don't have to keep 2 disks.  And insert both disks for the recovery.

But I found that Acronis True Image doesn't allow me to select my Samsung T7 storage (500G) in the rescue media builder <AcronisUSB.png>.

I made some search, and read (KB:58108) .  But seems my symptom is not exactly the same as that link descripted.  I tried to make a rescue media on a 128G SSD successfully, but it's difficult to buy that small size SSD storage (faster and more reliable) now.  I also tried to make a smaller partition on the 500G storage, but that doesn't work. 

Any method I can make a rescue USB with larger size? 

What's the maximum size USB the software allow me to create for a rescue media?

Will other new version of Acronis True Image (2021?) allow me to do that?

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AcronisUSB.png 107 KB
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Victor, welcome to these public User Forums.

The normal Acronis Bootable Rescue Media Builder tool cannot be used directly to create rescue media on an external USB disk drive as it is intended to be used with much smaller USB media such as memory sticks.

However, you can do this by adopting a different approach.

First, download a copy of the free MiniTool Partition Wizard software and install this on your PC.

Next, using the MiniTool application, create a new 2GB FAT32 partition at the start of your external USB disk drive by resizing the existing partition, or reformatting the whole drive to have 2 partitions, the new 2GB FAT32 partition and a new NTFS partition using the remaining space.

Allocate drive letters to both these partitions.

Now, you should be able to point the Acronis Rescue Media Builder tool to the drive letter for the 2GB FAT32 partition and it should be able to create the media in this partition.

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Steve, thank you for your reply.

I did according to your advise, but it seems still doesn't work for me.

Can you see anything I did wrong from my picture?

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Victor, I suspect that this is due to the age of the ATI 2016 rescue media builder program - this is definitely possible with later versions of ATI.

You can try using the MVP Custom PE Builder tool instead to create the media - that should see the new 2GB FAT32 partition drive letter and doesn't use the Acronis media builder tool.

See link in my signature for the MVP tool via the Acronis Community tools KB page and also the ATI 2017 Forum topic:  MVP Tool - CUSTOM ATI WINPE BUILDER