What I meant is that you have to go through the entire hard drive install. Install grub to the MBR. Boot into your new linux install.
Then from your running linux partition,
* Format drive as ext2
* Mount your usb hd (probably /dev/sda1) to some folder in /mnt (I'll use /mnt/sda1 as an example)
* Copy Grub files (stage1* stage2 and menu.lst) -- copy -a /boot/* /mnt/sda1
* Umount your usb hd.
* open grub as root
* device (hd1) /dev/sda # assuming usb device in linux is called /dev/sda
* root (hd1,0) # supposing you copy data in the first partition of the usb hd (the most usual)
* setup (hd1)
* quit
Then reboot with your pen drive in and the BIOS set to boot from USB drive, then CD, then Hard drive. Once it's working, you'll want to edit the hard drive's menu.lst so that it just boots Windows straight away. Then you can edit the USB key's menu.lst to boot linux straight away.
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