Hi Matt,
Make sure to format the CF Card IN the Fusion.
The Fusion's format utility does not only format the card, it creates other folders that the Fusion needs. . .
(Windows will just format it - which is why we don't use it)
Drop the .bin file in the ROOT of the CF card.
Back up your Fusion first by copying the <Volume> folder to your computer . . . .
Insert the CF card in the Fusion and power it on.
The Fusion should SEE the bin file and ask if you want to install the OS. . . .
Just follow the prompts - and that should be it . . . .
parametric