I booted up my Kali install and did the following:
The sdc1 partition is 8192M in size, half the size of the drive.
Code:
# fdisk /dev/sdc
Command (m for help): p
Disk /dev/sdc: 16.2 GB, 16231956480 bytes
141 heads, 32 sectors/track, 7026 cylinders, total 31703040 sectors
Units = sectors of 1 * 512 = 512 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0x45bab27f
Device Boot Start End Blocks Id System
/dev/sdc1 * 2048 8291 3122 b W95 FAT32
# mkfs.vfat /dev/sdc1
# dd if=kali.iso of=/dev/sdc1 bs=512k
dd: writing `/dev/sdc1': No space left on device
7+0 records in
6+0 records out
3146240 bytes (3.1 MB) copied, 0.218116 s, 14.4 MB/s
# dd if=kali.iso of=/dev/sdc bs=512k
# mount /dev/sdc1 /mnt/
mount: you must specify the filesystem type
# fdisk /dev/sdc
Command (m for help): p
Disk /dev/sdc: 16.2 GB, 16231956480 bytes
141 heads, 32 sectors/track, 7026 cylinders, total 31703040 sectors
Units = sectors of 1 * 512 = 512 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0x45bab27f
Device Boot Start End Blocks Id System
/dev/sdc1 * 64 4602239 2301088 17 Hidden HPFS/NTFS