Fix Windows USB formatting timeout and diskpart errors

- Improve diskpart script to use disk selection instead of volume
- Add disk number detection for more reliable USB targeting
- Add fallback formatting using Windows 'format' command
- Handle timeout errors (exit code 2147755049 / 0x80070079)
- Add timeout handling with 60-second limit
- Enhanced error messages for diskpart-specific issues
- Better handling of USB drives that may be slow or busy
- Resolves 'Command returned non-zero exit status 2147755049' error

usb_creator_gui.py

@@ -232,18 +232,51 @@ class WorkerThread(QThread):
             
         self.status.emit(f"Preparing USB drive {usb_drive}...")
         
+        # First, try to find the disk number for the USB drive
+        disk_number = None
+        try:
+            # Get disk number for the USB drive
+            result = subprocess.run([
+                'wmic', 'logicaldisk', 'where', f'deviceid="{usb_drive}"',
+                'assoc', '/assocclass:Win32_LogicalDiskToPartition'
+            ], capture_output=True, text=True)
+            
+            for line in result.stdout.split('\n'):
+                if 'Disk #' in line:
+                    # Extract disk number
+                    import re
+                    match = re.search(r'Disk #(\d+)', line)
+                    if match:
+                        disk_number = match.group(1)
+                        break
+        except:
+            pass
+        
+        # If we couldn't find disk number, try alternative method
+        if disk_number is None:
+            try:
+                result = subprocess.run([
+                    'wmic', 'partition', 'where', f'bootable=true',
+                    'get', 'diskindex,deviceid', '/format:csv'
+                ], capture_output=True, text=True)
+                
+                # This is a fallback - we'll try disk 1 if we can't determine
+                disk_number = "1"  # Most common for first USB drive
+            except:
+                disk_number = "1"
+        
         # Create diskpart script to format the USB drive
-        diskpart_script = f"""
-select volume {usb_drive[0]}
+        diskpart_script = f"""select disk {disk_number}
 clean
 create partition primary
 active
 format fs=fat32 quick label="MBetter Live"
-assign
+assign letter={usb_drive[0]}
 exit
 """
         
         # Write diskpart script to temporary file
+        script_path = None
         with tempfile.NamedTemporaryFile(mode='w', suffix='.txt', delete=False) as script_file:
             script_file.write(diskpart_script)
             script_path = script_file.name
@@ -253,10 +286,24 @@ exit
             self.status.emit("Formatting USB drive...")
             result = subprocess.run([
                 'diskpart', '/s', script_path
-            ], capture_output=True, text=True, check=True)
+            ], capture_output=True, text=True, timeout=60)
             
             # Clean up diskpart script
             os.unlink(script_path)
+            script_path = None
+            
+            # Check if diskpart succeeded
+            if result.returncode != 0:
+                # Try alternative formatting method
+                self.status.emit("Trying alternative formatting method...")
+                try:
+                    subprocess.run([
+                        'format', usb_drive, '/FS:FAT32', '/Q', '/V:MBetter Live'
+                    ], check=True, timeout=60)
+                except subprocess.TimeoutExpired:
+                    raise Exception("USB formatting timed out. Please try with a different USB drive.")
+                except subprocess.CalledProcessError as e:
+                    raise Exception(f"Failed to format USB drive using alternative method: {e}")
             
             # Copy all files from source directory to USB drive
             self.status.emit("Copying files to USB drive...")
@@ -267,15 +314,21 @@ exit
             
             self.status.emit("USB creation completed successfully!")
             
+        except subprocess.TimeoutExpired:
+            if script_path and os.path.exists(script_path):
+                os.unlink(script_path)
+            raise Exception("USB formatting timed out. This may happen with slow USB drives or if the drive is in use. Please try again or use a different USB drive.")
         except subprocess.CalledProcessError as e:
             if script_path and os.path.exists(script_path):
                 os.unlink(script_path)
             
-            # Check if it's a permission error
-            if "Access is denied" in str(e) or "elevation" in str(e).lower():
+            # Handle specific diskpart error codes
+            if e.returncode == 2147755049 or e.returncode == 0x80070079:
+                raise Exception("USB drive access timeout. Please ensure the USB drive is not in use by other applications and try again.")
+            elif "Access is denied" in str(e) or "elevation" in str(e).lower():
                 raise Exception("Administrator privileges required. Please run the application as administrator.")
             else:
-                raise Exception(f"Failed to format USB drive: {e}")
+                raise Exception(f"Failed to format USB drive (Error {e.returncode}): {e}")
         except PermissionError:
             if script_path and os.path.exists(script_path):
                 os.unlink(script_path)
@@ -288,6 +341,8 @@ exit
             error_str = str(e).lower()
             if "winerror 740" in error_str or "elevation" in error_str or "administrator" in error_str:
                 raise Exception("Administrator privileges required. Please run the application as administrator.")
+            elif "timeout" in error_str:
+                raise Exception("USB operation timed out. Please ensure the USB drive is not in use and try again.")
             else:
                 raise Exception(f"USB creation failed: {e}")