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Although Macs are reliable machines, they are not exempt from hiccups. All you need to do is carry around a single USB flash drive to be ready for situations the require you to diagnose, repair, or experiment with Mac OS X.

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One of the maintenance tools every Mac user should have available in case of emergency is a bootable copy of Mac OS X on a removable device. A clean installation of the operating system can help pinpoint problems and will come to the rescue in a bind. And since most Mac owners use a MacBook of some kind nowadays, portability is a valuable thing. That means carrying around a bulky external hard drive with cables is not always ideal. It turns out a tiny USB flash drive serves as a great alternative.

I am a new MAC user and I have a MAC running 10.1. I also have 4 install discs that are in an ISO format. When I place the Disc 1 into the MAC it is read and is able to mount the ISO. When it is mounted I can start the Install which really starts after the reboot. My problem is that the MAC is looking for the 'extracted' version of the ISO. Download Mac OS X 10.4 Tiger ISO, DMG installation files directly. Download the installation file for Mac OS X 10.4.6 Leopard PowerPC.iso. Download File OS X 10.4 Intel (Machine). Download OS X Leopard 10.4.11 Precompiled (Intel) Directly. Download Combo File Install Update (PPC) Mac OS X 10.4.10 for.

Not sure when having OS X loaded on a flash drive would come in handy? Here are just a few examples:

• Your Mac isn’t starting correctly and you’re not sure if the internal hard drive is failing or if another piece of hardware is to blame.
• The file system on your startup disk has become corrupt and needs to be repaired.
• A software problem is plaguing your Mac and you’d like to see if you can replicate it in an isolated environment.
• Your Mac’s hard drive is completely dead and you’d like to use your computer for basic tasks like email and web browsing while you wait for your new drive to arrive.

Now that you’re convinced, let’s figure out how to do this. First you’ll need an Intel-based Mac from the past few years. Second, at least a 16GB USB flash drive, such as this SanDisk Cruzer Micro for about $30 at Amazon. Keep in mind 10.6 Snow Leopard was used to demonstrate this tutorial, so I’m not sure how much space 10.5, 10.4, and earlier require. While they should be fine, squeeze those versions of Mac OS X on a 16GB drive at your own risk. And the third thing you’ll need to get the job done is your OS X installation DVD.

1. To start things off, connect the USB flash drive to your Mac. Make sure there’s no valuable data on there because it will be permanently wiped out in a couple minutes.
2. Open Disk Utility (Applications > Utilities) and click on your flash drive in the list on the left.
3. Go to the Partition tab and select “1 Partition” from the Volume Scheme menu. Enter a name for the volume (I called mine “OS X USB”), select “Mac OS Extended (Journaled)” as the Format, and make sure the size is somewhere around 15-16GB.
4. Click on the Options button towards the bottom and choose “GUID Partition Table” from the popup window. Click OK.
5. Now that all of the settings have been chosen, click the Apply button and then Partition. Disk Utility will take a minute or two to complete the task.
6. I don’t believe this step is required, but it makes me feel better and doesn’t hurt. Click on the volume name you entered in Step 3 (in the list under the flash drive’s name). Go to the Erase tab, make sure the Format is “Mac OS Extended (Journaled),” and click the Erase button.
7. Insert your Mac OS X installation disc if you haven’t already. A window should pop up with the contents of the disc. Double-click the “Install Mac OS X” icon and progress through the installer until you get to the screen that says “Mac OS X will be install on…”
8. Click the Show All Disks button and select your USB flash drive.
9. Click on the Customize button and a new window will appear. Un-check all of the items except “Essential System Software.” You may choose to check “Rosetta” and “QuickTime 7” since they are so small and might come in handy. Click OK and then Install. The rest of the process should be automated and might take between 30-60 minutes since USB flash drives are slower than internal hard drives. When all is said and done, you should find about 9GB of your 16GB drive has been filled.
10. Eventually, the installation will finish and it should reboot directly to the USB drive. If it doesn’t, restart the Mac manually and hold down the Option key to choose the drive yourself. This is how you will access it in the future, too.
11. Set up the fresh installation just like you would a new computer. Once you’re in, run Software Update a few times to get the latest patches and install any third party diagnostic utilities you may have. For example, Alsoft’s DiskWarrior is an invaluable tool that goes above and beyond what OS X’s own Disk Utility has to offer. This way both tools are available in one convenient place whenever you need them.

All done! That wasn’t too painful, was it? Yes, booting to the flash drive will be a tad sluggish, but it’s not meant to be used on a regular basis. This is mainly for diagnosing issues and trying potentially risky things in a virtual sandbox that won’t ruin any of your data. While you’ll hopefully never need to use it, having a bootable copy of OS X on a USB flash drive is a cost-effective, portable emergency tool for your Mac.

2006 – Mac OS X 10.4 Tiger ships on DVD media, which is great if you have a Mac equipped with a DVD drive (as most of us do these days), since the entire set of installer files can be contained on one disc, eliminating the necessity of disc-swapping in the middle of the process.

However, there are certain older Macs that are officially supported by a Tiger (i.e., that have built-in FireWire) but don’t have optical drives that support DVDs – notably some low-end iBooks and early low-end eMacs.

My Late 2002 iBook G3/700 has only a CD-ROM drive, and some of the education-only Macs were also CD-only.

Mac OS X Version 10.4 (PPC) requires a Macintosh with:

• PowerPC G3, G4, or G5 processor
• Built-in FireWire
• At least 256 MB of physical RAM (512 MB recommended)
• A built-in display or a display connected to an Apple-supplied video card supported by your computer
• At least 3 GB of available space on your hard drive; 4 GB of disk space if you install Xcode 2 developer tools
• DVD drive for installation (or get CD media from Apple for $9.95)

There are several possible workarounds. Apple will let you send in your Tiger install DVD along with $9.95 (details here), and they will replace it with a set of OS X 10.4 install CDs. If you don’t intend on upgrading your hardware in the near future and have no Mac with a DVD drive available, that may be the most convenient solution.

Another possibility is to purchase or borrow a freestanding, bootable FireWire DVD drive and run the installer from it.

A third possibility is to mount your DVD-challenged computer as an external hard drive from a DVD drive-equipped Mac via FireWire Target Disk Mode and choose its hard drive as the destination disk in the OS X 10.4 installer. That is the method I chose for installing Tiger on my iBook, using my Pismo PowerBook‘s DVD drive.

FireWire Target Disk Mode is a great innovation, even better than PowerBook SCSI disk mode was back in the SCSI era. It’s usually used for fast file transfers between computers and is the speediest interface for doing that, but it also works well for system or disk maintenance that requires mounting the drive from another boot volume and, as in this case, for system installations.

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To put my iBook into Target Disk Mode, I shut it down, and connected it to the PowerBook using a standard 6-pin FireWire cable (the same on both ends) usually used for connecting my external FireWire hard drive. I then started the iBook while holding down the T key, and in a few seconds the yellow FireWire symbol began bouncing around on the screen.

When I woke up the PowerBook, icons representing the iBook’s three hard drive partitions were there on the Desktop.

I inserted the OS X 10.4 install disc in the PowerBook’s DVD drive and clicked the Install icon, which made the PowerBook reboot from the DVD. When the installer screen came up, the iBook’s partition volumes were among the alternatives presented as an install destination.

The installation itself was straightforward. I chose to do an Archive and Install, and I checked the option to have the new system assimilate user settings from a former system, avoiding the tedium of going through the Setup Assistant routine.

In my case, I also chose not to install the 1.62 GB of printer drivers, the extra fonts, and the language support files in order to conserve hard drive space on the iBook’s 20 GB hard drive.

My basic installation took about 20 minutes. After the installer displays its “Installation Of Software Successfully Completed ” dialog, it wants to reboot into the new system it has just installed. I discovered no way to defeat this, so the Pismo rebooted from the iBook’s hard drive, which was interesting. No problems were encountered, though.

At that point I shut down both computers, disconnected the FireWire cable, and restarted each computers from its respective boot system.

In that instance, the Previous System Folder containing my old OS X 10.3.9 Panther installation turned out to be more than 5 GB, while the new Tiger system folder was less than 1.5 GB. That Panther (10.3.x) install actually dated back to my installation of OS X 10.2.3 Jaguar in January 2003, when the iBook was new and after I had partitioned the hard drive. It had only been updated since then – many times – never with a clean system reinstall.

Doing a clean installation (save for the imported settings), recovered 4 MB of free hard drive space. Emptying the Trash containing the Previous System Folder took nearly half an hour and deleted some 90,000 files!

Using this method proved to be a successful workaround for getting Tiger into my iBook, and I expect it would work for installing Tiger on older, officially unsupported Macs using the XPostFacto installer hack, although I can’t say for sure, having never tried it.

Further Reading

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• Using FireWire Target Disk Mode to Install OS X on Macs Without DVD Drives, Charles W Moore, Miscellaneous Ramblings, 2006.09.14. Two methods for using FireWire Target Disk mode to install OS X on a Mac that can’t read DVDs.

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