The actual size of the disk is not the same as what is available to use, there is some reason for it, to do with block sizes and reserved areas and other bumf like that If you want to create a boot disk you can either goto http://www.bootdisk.com/ they have a number of boot floppy images, or on any windows machine (except windows 2000) you can right click on the floppy and select format, in there is an option to create a startup disk. You cant create a boot floppy by just copying the files over to the disk.