Posted 17 October 2012 - 10:01 PM
2 years after this thread was started, this bug gave me a headache before, but I found a solution that I hope might help others save time and frustration:
I had the same symptom as Larry, ie, a "Space isn't sufficient" message box even for Damn Small Linux, which is a 50M distribution. I use Win 7.
The root of the problem in my case is that I was running Sardu 2.05 from a NAS (network share), and as soon as I copied it to the C: drive and ran from there, the USB drive was configured without errors.
I believe the problem is that Win7 added some new 'security', where programs residing on network shares don't run without a 'security' prompt. So when Sardu attempted to run the 7zip utility in the same directory, windows probably denied the execution request, which Sardu assumed it is because of 'insufficient space'.
I suggest to the author to fix this bug, either by interpreting and reporting the error correctly, or changing the implementation so that no other .exe are run as subprocesses, and instead import the needed 7zip routines directly from a dll. Or both.
Thanks for an otherwise useful utility, and I hope this helps someone.