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ReImageing Workstation problem

I have a backup Image (made with windows 7) of my test workstation I wish to roll out to a number of workstations.

The process has worked fine for a number of workstations, but have had issues with a small number which are slightly different specs of those that worked (in as CPU differs, m/board and internals may be different, HDD same size).

After booting the WS from the Win7 install DVD (with USB HD plugged in that has image) and choosing to Repair the system by installing the image on USB the process fails.

WS recognises USB with the Image all the way through the process and finds the Image.
At the point where it has options to reformat the existing HD in WS (which is preselected and unable to deselect) - after this it fails.

The error implies it can't find either the Image (which it clearly recognised all the way through) or the WS HDD or partitions?

Note: When this same process was followed using the same USB HD with Image the option to reformat WS HDD was deselected and you could select if required. On this occasion it is selected and you can't change it.

Any suggestions are welcome.
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AIGS
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AIGS
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Lee W, MVPTechnology and Business Process AdvisorCommented:
I would suggest doing this properly.  Your method is unsupported and leaves the potential for problems with the deployed workstations - weird things not working properly now... or later should an update change something.

To properly create an image, you need to boot into Audit mode after installing from a volume license DVD and configure/customize as you need.  Then you MUST (this is NOT optional) reseal the image with Sysprep.  THEN you take the image using whatever software you want (I recommend using the Microsoft tools since they are basically free/included with Windows server - the Microsoft Deployment Toolkit (MDT), Windows Deployment Services (WDS), and the Assessment and Deployment Kit (ADK).

You'll have a MUCH better experience overall
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AIGSAuthor Commented:
Update:

Point you have made has been taken. In the meantime I have since discovered that the size of the HD the image was to be put on is in fact smaller than the image.
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Lee W, MVPTechnology and Business Process AdvisorCommented:
That's one problem with the backup program - it's unable to restore to drives smaller.  A proper imaging solution is hardware independent and doesn't care what size the drive is, so long as there is enough space to deploy the image.
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