Pfsense USB Installation Guide

While the below method still works, it has now been superseded by Pfsense USB Install Guide (Rufus)

I have been doing pfSense installs for a long time using USB install media, however the install media was built by hand using syslinux. While the old process worked fine, it was a little cumbersome. So about 9 months ago a co-worker of mine found a nice little tool that completely changed the way we build pfsense USB install media. The tools is called USB Image Tool and is written by Alexander Beug. This tool alone literally takes all the guess work out of creating the install media. With that said, here is the new process:

  1. Download the latest compatible version of pfSense in .img.gz format. Note: the file name should include “memstick”.
  2. Plug in an empty USB stick and fire up the USB Image Tool.
  3. Restore the image onto the USB stick using USB Image Tool (See Image).
  4. Insert the newly created USB stick into router.
  5. Boot into the BIOS of the router and set “USB – HDD” to the top of the boot order. (On Hacom routers, press Del to enter the BIOS).


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