This is still a problem. In my case it is definitely an issue with the
file size limitations of vfat. I tried to make a persistent usb with
jaunty 9.04 beta DVD. Everything went fine and no errors were reported.
The usb boots up fine but nothing is persistent across reboots. I went
ahead and tried to recreate the USB from the live DVD but this time I
looked more carefully at the log in ~/.usb-creator.log. I allocated 5 GB
in usb-creator and here is the error in my log:
['dd', 'if=/dev/zero', 'bs=5378073556', 'of=/media/DIESEL/casper-rw', 'count=1']
dd: invalid number `5378073556'
['mkfs.ext3', '-F', '/media/DIESEL/casper-rw']
mke2fs 1.41.4 (27-Jan-2009)
mkfs.ext3: No such file or directory while trying to determine filesystem size

so it failed to create the casper-rw file, but no errors were reported
in the gui. The gui indicated that the usb was created successfully and
that I should reboot to use it. Ideally when vfat is being used the size
should be automatically limited to 4GB with a note indicating why
(otherwise you will have a bunch of new bug reports saying it won't let
them use more than 4GB). At a minimum when there is an error like this
with dd then usb-creator shouldn't exit without any indication that
there was a problem.

I will try again but use less than 4 GB just to confirm that it is the 4
GB size limit that is the problem.

-- 
[Intepid] Ubuntu Live USB creator creates liveUSB's that are limited in size
https://bugs.launchpad.net/bugs/284085
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