DEVICE=loop
MOUNT=/tmp/staging
NAME=test.img

dd if=/dev/zero of=$NAME bs=512 count=1250000
losetup /dev/${DEVICE}0 $NAME
dd if=_BOOT/boot/syslinux/mbr.bin of=/dev/$DEVICE conv=notrunc
parted -s /dev/${DEVICE}0 mklabel msdos
parted -s -a cyl /dev/${DEVICE}0 mkpart primary ext2 '63s' '100%'
parted -s /dev/${DEVICE}0 set 1 boot on
sleep 2
losetup -d /dev/${DEVICE}0
losetup -o $(( 512 * 63 )) /dev/${DEVICE}0 $NAME
mkfs.ext2 -L FIRMWARE /dev/${DEVICE}0
mount /dev/${DEVICE}0 $MOUNT
*copy files*
extlinux --install ${MOUNT}/boot/syslinux
umount /dev/${DEVICE}0
losetup -d /dev/${DEVICE}0




Command (m for help): x

Expert command (m for help): p

Disk /dev/loop0: 54 heads, 55 sectors, 420 cylinders

Nr AF  Hd Sec  Cyl  Hd Sec  Cyl     Start      Size ID
 1 80   1   1    0 206  17   77         63    1249937 83
 2 00   0   0    0   0   0    0          0          0 00
 3 00   0   0    0   0   0    0          0          0 00
 4 00   0   0    0   0   0    0          0          0 00