Comment 47 for bug 458334

I tried all of the suggestions and nothing worked. I finally did get it ot work.
The key in my case seems to be to limit the size of the partition. I I made it 1GB.
I was using a 16GB stick. I did this with parted.

First I started by "dd"ing the first 1M with zeros as suggested to make sure
I started with a clean slate. In my case the usb stick was /dev/sdb

if /dev/sdb1 is mounted, unmount it:

  sudo umount /dev/sdb1
  sudo dd if=/dev/zero of=/dev/sdb bs=1M count=1

Then in parted: "sudo parted /dev/sdb" make a msdos label
and a fat16 partition. The "unit" command allows inputs in
MB where 1000MB = 1GB.

  unit MB
  mklabel msdos
  mkpart primary fat16 0 1000
  quit

Then to format it:

  sudo mkfs -t vfat /dev/sdb1

Now usb-creator should work. I did the procedure a couple of times
and for some reason sometimes usb-creator still thinks it needs to
format and when it did I selected /dev/sdb1 to format
Sometimes it was fine without the format.

After this I could start the create.

If you don't do the formatting using mkfs.vfat, ie just the parted stuff,
usb-creator will change the partition to 16GB (in my case),
try to partition and fail. I don't know that much about vfat, but
could it be that it is size limited and usb-creator is not taking that
into account?