OK, i tried finding what i did wrong by reading the posts and links you pointed me to, but did not (yet) suceeed.
Here are some more details, maybe someone can give me a hint.
my txtsetup.sif ist attached
My target dir looks like this:
30.07.2008 19:48 <DIR> boot
02.11.2006 22:00 438.840 BOOTMGR
30.07.2008 19:49 1.054 menu.lst
30.07.2008 19:48 <DIR> Programs
30.07.2008 19:48 <DIR> RECO
30.07.2008 19:48 673 vistape.cfg
30.07.2008 19:49 86.654.499 vistape.wim
my usb root looks like this
30.07.2008 14:54 <DIR> boot
02.11.2006 22:00 438.840 BOOTMGR
30.07.2008 14:51 192.009 GRLDR
30.07.2008 14:51 1.054 menu.lst
30.07.2008 14:54 <DIR> Programs
30.07.2008 14:54 <DIR> RECO
30.07.2008 14:50 673 vistape.cfg
30.07.2008 14:51 86.654.543 vistape.wim
My menu.lst looks like this:
CODE
splashimage /boot/gentleblue.gz
timeout 30
default 0
title VPE c't edition
chainloader /BOOTMGR
title Parted Magic Linux 2.2 (Runs from RAM)
kernel /boot/plinux/kernel.pml vga=788 noapic root=/dev/ram0 squashfs=/boot/plinux/pmagic.fs pmodules=/boot/plinux//pmodules init=/linuxrc ramdisk_size=200000 keymap=us liveusb quiet toram
initrd /boot/plinux/initrd.pml
title Windows XP SP2 Recovery Console German
chainloader /RECO/SETUPLDR.BIN
title Find and Load NTLDR of Windows NT/2K/XP
find --set-root /ntldr
chainloader /ntldr
title Find and Load CMLDR of Windows NT/2K/XP
find --set-root /cmldr
chainloader /cmldr
title find and load IO.SYS of Windows 9x/Me
find --set-root /io.sys
chainloader /io.sys
title find and boot Linux with menu.lst already installed
find --set-root /sbin/init
configfile /boot/grub/menu.lst
title MemTest86+
kernel /boot/memtest.bin
title Floppy (fd0)
chainloader (fd0)+1
rootnoverify (fd0)
title CommandLine
commandline
title Reboot
reboot
title Halt
halt
the recovery console was made with the recc.script from vistape12b3. Here is the basic code (not complete, removed everything not relevant just to show what is done)
CODE
Echo,Downloading requested files...
WebGet,"%DL_GERMAN%","%TmpFolder%%pScrollBox1%\WindowsXP-KB310994-SP2-Pro-BootDisk.exe"
Echo,Extracting downloaded files...
ShellExecute,hide,"%Tools%\7z.exe","x -y #$q%TmpFolder%%pScrollBox1%\WindowsXP-KB310994-SP2-Pro-BootDisk.exe#$q -o#$q%TmpFolder%%pScrollBox1%#$q"
ShellExecute,hide,"%Tools%\extract.exe","-x #$q%TmpFolder%%pScrollBox1%\cdboot1.img#$q #$q%TmpFolder%%pScrollBox1%#$q"
ShellExecute,hide,"%Tools%\extract.exe","-x #$q%TmpFolder%%pScrollBox1%\cdboot2.img#$q #$q%TmpFolder%%pScrollBox1%#$q"
ShellExecute,hide,"%Tools%\extract.exe","-x #$q%TmpFolder%%pScrollBox1%\cdboot3.img#$q #$q%TmpFolder%%pScrollBox1%#$q"
ShellExecute,hide,"%Tools%\extract.exe","-x #$q%TmpFolder%%pScrollBox1%\cdboot4.img#$q #$q%TmpFolder%%pScrollBox1%#$q"
ShellExecute,hide,"%Tools%\extract.exe","-x #$q%TmpFolder%%pScrollBox1%\cdboot5.img#$q #$q%TmpFolder%%pScrollBox1%#$q"
ShellExecute,hide,"%Tools%\extract.exe","-x #$q%TmpFolder%%pScrollBox1%\cdboot6.img#$q #$q%TmpFolder%%pScrollBox1%#$q"
ShellExecute,hide,"%WindowsDir%\System32\expand.exe","-r #$q%TmpFolder%%pScrollBox1%\TXTSETUP.SI_#$q #$q%TmpFolder%%pScrollBox1%#$q"
#remove junk
FileDelete,"%TmpFolder%%pScrollBox1%\WindowsXP-KB310994-SP2-Pro-BootDisk.exe"
FileDelete,"%TmpFolder%%pScrollBox1%\makeboot.exe"
FileDelete,"%TmpFolder%%pScrollBox1%\makebt32.exe"
FileDelete,"%TmpFolder%%pScrollBox1%\cdboot1.img"
FileDelete,"%TmpFolder%%pScrollBox1%\cdboot2.img"
FileDelete,"%TmpFolder%%pScrollBox1%\cdboot3.img"
FileDelete,"%TmpFolder%%pScrollBox1%\cdboot4.img"
FileDelete,"%TmpFolder%%pScrollBox1%\cdboot5.img"
FileDelete,"%TmpFolder%%pScrollBox1%\cdboot6.img"
FileDelete,"%TmpFolder%%pScrollBox1%\TXTSETUP.SI_"
#patch setupldr.bin to find its files in the recc folder insted of the i386 folder
ShellExecute,hide,"%Tools%\sfk.exe","rep #$q%TmpFolder%%pScrollBox1%\SETUPLDR.BIN#$q -yes -text /i386/RECO/"
#replace some strings in original txtsetup.sif
TXTReplace,"%TmpFolder%%pScrollBox1%\TXTSETUP.SIF","1=%cdname%,%cdtagfilei%,,\i386","1 = %cdname%,%cdtagfilei%,,\RECO"
#replacement order does matter
TXTReplace,"%TmpFolder%%pScrollBox1%\TXTSETUP.SIF","win51ip.sp2",%tagfile%
TXTReplace,"%TmpFolder%%pScrollBox1%\TXTSETUP.SIF","win51ip2",%tagfile%
TXTReplace,"%TmpFolder%%pScrollBox1%\TXTSETUP.SIF","win51ip",%tagfile%
TXTReplace,"%TmpFolder%%pScrollBox1%\TXTSETUP.SIF","win51mp",%tagfile%
#copy to target
FileCopy,"%TmpFolder%%pScrollBox1%\*.*","%TargetDir%\RECO"
If,ExistFile,"%TmpFolder%%pScrollBox1%\BOOTFONT.BIN",FileCopy,"%TmpFolder%%pScrollBox1%\BOOTFONT.BIN","%TargetDir%\BOOTFONT.BIN"
#add to grub
TXTAddLine,"%MenuFile_GRUB%","title Windows XP SP2 Recovery Console %pScrollBox1%","Append"
TXTAddLine,"%MenuFile_GRUB%","chainloader /RECO/SETUPLDR.BIN","Append"
TXTAddLine,"%MenuFile_GRUB%"," ","Append"
the created recoverconsole works when bootet from the iso (created from the obove target dir)
Any hints are welcome, thanks!