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Make a partition the size of the image, then run the dd command again on that partition. You may want to add bs=512 to the end, that's how the Slackware USB image is created. This may not work properly though, with the Slackware USB install image you have to use the entire thumb drive, regardless of how large it is. At least that's how it is done according to the official notes.
503box:/media/disk# dd if=/dev/sda of=503box.img count=484526190
3905407+0 records in
3905407+0 records out
1999568384 bytes (2.0 GB) copied, 156.178 s, 12.8 MB/s
so what now??
it should make a img file of exactly the spce taken up by whats on usb...
how do I do that and have it be bootable?
Have you tried manually copying the files into a directory outside of the drive, then turning that directory into a .img? I am downloading the small debian.img from the link you gave, I will mount it and take a look at how it's set up, if it's just a standard Linux system converted into a .img you should have no problems doing what I just suggested.
Edit: I did a quick search on Debian live image and found this on the Debian wiki. That goes through making a live image containing whatever parts of the system you want, you can use it to replicate your current image. But I would still try out the partimage method, it creates an image of the drive without the free space, so you would have what you were originally trying to do with dd.
Edit2: I just looked at the file, as long as your current USB image is able to boot you will be able to copy the contents into a directory and then make an image of them and stick it back on a disk.
Well you would have to make the image with the lh_{whatever} commands, they are in the Debian wiki on creating live images. I should have probably mentioned that before. Have you tried just using partimage yet?
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