Using an external hard drive would probably be the best option. 

Hi, 

Please view this video and confirm if you are following the same steps to create the recovery drive.

Yes. The problem is I need 32.9 GB of space and even on a new Thumb drive I have used 3 diff ones all 64 GB and fresh out of packages all from different manufactures. When inserted AlienRespawn gives same message. You have inserted a disk that can not be partitioned and will format 32. GB blocking used portion from being used thus my problem    I need 32.9 its a 64GB and the program only sees 32 GB because I thing in needs Fat 32 and that can only format 32GB

Hi, 

Did you also try formatting the thumb drives? You can do this by right clicking on the drive and selecting the "Format" option. 

Yes but I feel it need Fat 32 that can only be formated up to 32GB only option i get is to formate as NTFS or extra fat (?)

Hi, 

Can you please confirm which version of Alien Respawn you're using?

It shows 1.9.0.22  and I have run update

Hi, 

Thanks for confirming this. What happens if you choose the extra FAT option on the format settings of the thumb drive?

it makes no difference witch format I use both have same outcome

Hello, 

I’m sorry I did not reply earlier, I was out of the office. I found this thread which may be useful in this case. 

You can close this I had to buy an external hard drive the thumb drive will not work for creating a factory image. The article you referred to is for a bootable drive  in case the computer will not boot. That I already did and that will work on a thumb drive

Thank you for confirming this.