Make an E2B USB drive using RMPrepUSB (Windows)

Instructions for making an E2B USB drive under linux are here.
WARNING: If using a large USB hard disk, make sure the E2B is in the first partition and it is below 137GB.
Many BIOSes (even modern ones!) have a problem accessing USB drives beyond 137GB!
Note: Windows can only access the first partition on a Removable USB Flash drive. For a multi-partition USB drive, use a 'Fixed-disk' type of USB drive.
E2B disks must be MBR-partitioned and less than 2TB - GPT partitions are not supported.
1. Downloa d and install the latest version of RMPrepUSB (or use the portable version).
2. Download Easy2Boot (either the basic download or E2B+DPMS\XP MassStorage drivers)
3. Insert your USB Flash drive (a USB HDD can be used but a USB Removable flash drive will give the most trouble-free results). 
4. Run RMPrepUSB and tick the 'No User Prompts' checkbox and select (see screenshot below):
Tips: Tick the 'No user prompts' checkbox to reduce the number of prompts!
        To show large USB drives press Ctrl+Z.
Note: Some 'bad' BIOSes will boot a single-partition USB drive as a 'super-floppy' drive - but E2B needs to always be booted as a 'hard disk'. If however a USB drive contains 2 or more partitions, it should always be booted correctly by all BIOSes as a USB 'hard disk'.
If you tick the Boot as HDD (C: 2PTNS) option, a small, unused, unformatted, hidden Type 21h partition will also be made by RMPrepUSB - this is so that it will always boot as a 'hard disk'. If you intend to add your own 2nd partition, do not tick the Boot as HDD (C: 2PTNS) option and then you can later add more partitions by using a different partitioning utility.
RMPrepUSB settings
Note: Partition size is in MB (e.g. 137000 = 137GB)
To partition and format a drive, RMPrepUSB is numbered 1 to 6 for the six steps
4.1 Partition SizeMAX or 137000   (tick No user prompts) - if you want more than one partition then specify a smaller size for the first partition. Recommended maximum 137000.
4.2 Volume Name - Easy2Boot (or whatever name you like!)
4.3 Bootloader Options - WinPE v2 [BOOTMGR] (any except SYSLINUX will work)
4.4 Filesystem and Overrides - either choose FAT32 + Boot as HDD  (or NTFS + Boot as HDD - recommended)  - FAT32 is faster and more compatible with a wider variety of OS's, but you can't have files >4GB with FAT32! exFAT is an alternative option but is not recommended as it cannot be accessed by XP/Vista/Win7RTM and does not work with the Switch_E2B.exe utility.
If you are going to create a multiple-partition USB drive, do NOT tick the 'Boot as HDD' option and set the Partition Size to a smaller size (Note: 137000MB is recommended maximum size for an E2B partition, due to some BIOSes having problems with larger USB partitions).
4.5 Copy OS Files - click 'Choose Source'  answer Copy Files='NO' (because we want to extract  the ZIP file contents, not copy it to the drive) and set to the path of the Easy2Boot .zip file you downloaded in step 2.   
4.6 Prepare drive (this will erase all the USB partitions and drive contents)
After clicking '6 Prepare Drive' the drive should be formatted and the zip file unpacked and copied to the USB drive.

5. Now, click on Install grub4dos button (see screenshot above) - answer 'No'=PBR.  

   Run 'Install grub4dos' TWICE - answer No for the first time and Yes for the second time.

Always use  grldr=CANCEL when prompted to overwrite it, so that you do not overwrite the E2B grldr file with an older version.

 Always use the version of grldr included with E2B

6. Repeat step 5 but answer 'Yes'=MBR - grldr=CANCELdo not overwrite the E2B grldr file when prompted to overwrite it.

Check: The \grldr file should be the same one that is included in the E2B download.

Note: If you intend to use .imgPTN files (e.g. for UEFI booting), you must install grub4dos to the MBR (as well as the PBR).
Check that the Easy2Boot file that you downloaded earlier has been extracted onto the root (top level) of the USB drive. There should now be a \_ISO folder on the USB drive. The top level (root) should also contain several files including \grldr and \menu.lst.
Note: For best bootability/compatibility, you should always have two Primary partitions present on the USB drive. This ensures that it will always boot correctly as a USB HDD and not a USB FDD (flashing cursor!) on some systems. If you E2B drive has only one Primary partition, add a second Primary partition of any size and type. You can use RMPrepUSB - DriveInfo - 0 to view the partition table.
Your USB E2B drive is now complete, but you might want to add ISO and other payload files, so now...
go to the Adding Payload Files page.
Note: For direct MBR-booting from .VHD, .VHDX and .WIM files, you will need to copy a Windows 8/8.1 version of C:\bootmgr to the \_ISO\e2b\grub\DPMS\NTBOOT.MOD folder. More details here.
Only certain Windows 8/8.1 versions of bootmgr will work, do not use the Windows 10 version of bootmgr as it will give a BSOD.
Bootmgr versions that work are sizes 398,156; 427,680; 398,356; 404,250; 409,154; 403,390 or 400,517 bytes.

Multiple Partitions

For a multiple-partition USB drive, you should have used RMPrepUSB to make the first partition and untick the Boot as HDD (C: 2PTNS) option so that only one partition is made, and set the Size to what you want for the first partition. For the other partitions, you can now add multiple Logical partitions - OR - add one single Primary partition. 

You can use any partitioning tool to add the other partitions such as Windows Disk Manager or EaSeus Home Partition Master (free). 

E2B will not load the Main Menu unless the 4th partition table entry is unused\empty.

E2B may also require the 3rd partition table entry to be unused\empty for some linux+persistence payloads, but it does not have to be unused if you really need it.

I recommend you either add:
  • Any number of Logical partitions

To check that only two of the four partition table entries have been used, use RMPrepUSB - Drive Info button - 0  to list the partitions in LBA 0 (the MBR) of the USB drive. 

To be able to use all features of E2B, the 3rd and 4th partition entries must be unused. e.g.

P1   Start=63 (32,256 bytes) End=2,050,729,379 (1,049,973,442,048 bytes)
P2   Start=2,050,745,440 (1,049,981,665,280 bytes) End=3,906,959,804 (2,000,363,419,648 bytes)
Note that for 'Removable' USB drives, Windows will only mount and access the first partition on the drive. Unless you are very familiar with disk partitions, etc. I suggest you do not create additional 'usable' partitions on a 'Removable' type USB drive - just tick the 'Boot as HDD (C:)' option.
Tip: You can make the second partition on a Removable USB drive accessible to Windows by using RMPrepUSB - CTRL+O - 2   or \_ISO\SWITCH_E2B.exe - 'Access Partition 2 on a Removable Drive'.
  • Installing grub4dos to both the MBR and PBR, and having more than one partition on the USB drive improves 'bootability' on a wider range of systems. 
  • If you have more than 2 partitions on the drive and one of them is the RMPrepUSB dummy Type 21h partition, then delete the dummy Type 21 hex partition as it is not needed if you have more than one partition.
  • You can add payload files to the 2nd partition and add a menu entry which allows you to select any of the payload files from a menu. See the \_ISO\docs\Sample mnu Files\E2B Menus folder for example PTNxxxxx.mnu files. 
  • Note that if a BIOS has the 137GB USB bug (very common even today!) then it will not be able to boot from any files in the 2nd partition, if that partition starts after the 137GB point on the USB disk! If possible, keep all E2B files in the first 137GB from the start of the USB disk.

Use an existing USB drive

If you already have a grub4dos bootable USB drive, just extract the E2B zip file contents to your USB drive (don't overwrite your own \menu.lst file). I strongly recommend you use the E2B version of the \grldr file. Many other versions of grub4dos have bugs!

You can then add a menu entry into your \menu.lst file to load the E2B Main menu, e.g.

title Easy2Boot \nLoad the Easy2Boot Main menu.
if exist (bd)/_ISO/e2b/grub/E2B_GRUB.txt set grub=_ISO/e2b/grub
if not exist (bd)/%grub%/E2B_GRUB.txt echo SORRY - CAN'T FIND E2B_GRUB.txt file (please edit \menu.lst file)! && pause && commandline
configfile /%grub%/menu.lst
See here for more details.
Note: If you have a \EFI folder already present and your first partition is FAT32, on some UEFI systems this may prevent MBR-booting to grub4dos and E2B. Unless you really need EFI boot files, I suggest you delete the \EFI folder from your USB drive as it is not needed by E2B and you can boot to UEFI-payloads using .imgPTN files.