i tried the recommendation of USB Image Tool ver 1.80, from tinkertry.com/clone-esxi-with-usb-image-tool today. though he used 1.74 during his write up.
my original main ESXi USB stick was working fine but after i made a backup it no longer works. i get the Bank 5 Back 6 error that others have had. if i had read the comments before proceeding i would have seen Alex's post linking this link, https://www.alexpage.de/forum/viewtopic.php?f=1&t=534&start=10.
so i formatted another USB stick and had USB ITool restore the recent backup image to it. same ESXi boot errors.
i did have the option "Fix GPT after Restore" checked for both backup & restore.
i see another user at thread, "Re: USB with Hypervisor ESXi 5.1 image" post his results from sgdisk print out. so here is mine...
with what sgdisk is showing, is there a way i can get this esxi stick to boot properly?
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sudo sgdisk --print /dev/sdb Disk /dev/sdb: 30031872 sectors, 14.3 GiB Sector size (logical/physical): 512/512 bytes Disk identifier (GUID): 41510505-AFF5-45DB-BDCB-6487E5227584 Partition table holds up to 128 entries Main partition table begins at sector 2 and ends at sector 33 First usable sector is 34, last usable sector is 30031838 Partitions will be aligned on 32-sector boundaries Total free space is 22945917 sectors (10.9 GiB) Number Start (sector) End (sector) Size Code Name 1 64 8191 4.0 MiB EF00 2 8224 520191 250.0 MiB 0700 3 520224 1032191 250.0 MiB 0700 4 1032224 1257471 110.0 MiB FC00 5 1257504 1843199 286.0 MiB 0700 6 1843200 7086079 2.5 GiB FC00