I will be contributing to the pauldotcommunity blog site moving forward. You will find posts in both this blog and global-security. Hopefully we will be able to publish some useful information in at least one of these locations :-P
Since we have been building LiveUSB tools that were based on FreeBSD there has historically been an issue with several makes of laptop/hardware on boot. This problem has manifested in many ways but always yields the same result; a non-working LiveUSB tool for the system owner. This problem had to do with the BTX Loader not playing well with the specific hardware in question and not loading/running properly via USB.
The good news is that recently a patch was released that should rectify this issue! I will be applying this patch to all FreeBSD based LiveUSB releases going forward. Thanks for all of the community feedback and support on all of this.
Look for the new HeX 2.0 to be out soon, all based on FreeBSD 7.0R!
Note that some usb sticks will be smaller than others (even if it's "2G") and that even if you write it and dd produces an error saying that not enough space is available... this is OK and your HeX LiveUSB will still work fine.