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I find it strange that OPNsense employees don't take more interest in this thread...

I still haven't had time to burn a DVD, but when I do, I will report the results back to this thread.

Thanks for the replies!  :D

I've tried both Win32diskimager and OPNsense-16.7-OpenSSL-cdrom-XXXX.iso.bz2 suggestions without success.

I also tried booting from my main PC (MB: ASUS Sabertooth 990FX, BIOS Version 1503). It tries to boot, but gets into some loop and I see "GPT" error flash really quick on the screen, which may be the same message shown on my dd2.png screenshot in red.

I even tried FreeBSD-11.0-RELEASE-i386-memstick.img, same issue, which leads to be believe there is something fundamentally wrong with FreeBSD boot loader compatibility. For example, Rufus 2.11 refuses to even load any of the OPNsense-16.7-OpenSSL-XXX-XXX.iso files.

I've never had these issues with either Windows or Linux ISO files, they just work (boot)!!!

It seems my only option is to burn a physical DVD... which is disappointing.  :(

I downloaded OPNsense-16.7-OpenSSL-vga-amd64.img.bz2, then ran

bunzip2 -d OPNsense-16.7-OpenSSL-vga-i386.img.bz2

then

sudo dd if=OPNsense-16.7-OpenSSL-vga-i386.img of=/dev/sdb bs=1M

it writes successfully to the USB thumb drive, but it's not recognized as bootable media when I plug it into my test PC.

I used bs=1M because another thread with similar issue said changing that value from 16k could help.

My environment: Windows 10 Pro, with Ubuntu 16.04.1 running on VirtualBox 5.1.10

If I do the same with ipfire-2.19.x86_64-full-core102.iso it works fine and my test PC boots into the ipfire installer.

From what I think I learned, it seems the ipfire ISO is "hacked" to work with USBs, but the OPNsense ISO is not (only works with CD/DVDs) so I'm only trying to use your IMG files.

I've also tried using different USB media but with same bad result.

I also tried using rufus-2.11 but with same bad result.

I'm new to FreeBSD and new to OPNsense, and I'm trying to migrate from ipfire to OPNsense.

I've attached two images, the first one (dd1.png) show the fdisk info before the dd script and the result of the dd script. The second image (dd2.png) show the fdisk info after successfully (?) writing to the USB.

Any help with this would be appreciated  :)

My fall-back option is to use the ISO image and burn a DVD, but I'm trying to avoid that.