Don't worry! It's only stuff...

#!/bin/bash
 
DEVICE=/dev/sdb
ISO=ubuntu-9.04-desktop-i386.iso
VOLUME=USB_4GB
 
sudo su
 
# install needed apps
sudo apt-get install -y syslinux mbr mtools
 
# OPTIONALY format drive 
# sudo umount ${DEVICE}1
# sudo mkfs.vfat -n ${VOLUME} ${DEVICE}1
 
# install mbr and syslinux
mkdir /tmp/${VOLUME}
sudo mount ${DEVICE}1 /tmp/${VOLUME}
sudo install-mbr ${DEVICE}
sudo syslinux -f ${DEVICE}1
#sudo syslinux -smf ${DEVICE}1
 
sudo mount ${ISO} /mnt/ -o loop
cp -a /mnt/.disk/ /media/${VOLUME}
cp -a /mnt/casper/ /media/${VOLUME}
sudo umount /mnt
 
cat <<EOF>> /tmp/${VOLUME}/syslinux.cfg
TIMEOUT 10
LABEL linux
MENU LABEL ${ISO%.*}
KERNEL /casper/vmlinuz
APPEND boot=casper initrd=/casper/initrd.gz quiet splash --
EOF
 
sync
umount /tmp/${VOLUME}
 
# TODO
# include DISTRO part from pxe boot
 
# LINKS
# http://wiki.ubuntuusers.de/Live-USB
# Casper parameter (from live-helper package)
# /usr/share/live-helper/templates/casper/parameters.txt
# http://debian-live.alioth.debian.org/
# http://www.pendrivelinux.com/usb-boot-cd-for-ubuntu-810/
# http://wiki.ubuntuusers.de/Live-USB