Have you verified checksums each time? If not, I start from there.
You uncompressed it? bz2 is not the raw image. Use 7zip.
but writing USB key fail with all imagesTry it again with 21.7 and it worked so is there a problem with the new image ?It's not the first time it fails like that with opnsense images, I can't remember the last time it happened but it happenedDid someone make it work ?
I made my flash drive with the OPNsense installer using Rufus by feeding it an uncompressed image.
Did you do it on windows ?