How to Format and Label a bootable 20G file-as-a-filesystem?

I'm trying to create a bootable 20G file that has a UFS filesystem.
I'm starting with a bootable Compact Flash (CF) that's 32G, has a UFS file system, and I'd like to "remaster" the 32G CF into a 20G file, then create bootable CF's with "dd" from the 20G file on a Windows "Mastering" machine.
Here's what I've tried:
Create a 20G file:
dd if=/dev/zero of=/export/home/20G bs=1024k count=20000
Add file as a block device
lofiadm -a /export/home/20G
Create a UFS filesystem on the new block device
newfs /dev/lofi/1
Create a new mountpoint for the 20G filesystem
mkdir /export/home/mnt
Install UFS bootblock on the new 20G file system
installboot /usr/platform/sun4v/lib/fs/ufs/bootblk /dev/rlofi/1
Mount the new filesystem
mount /dev/lofi/1 /export/home/mnt
Copy all files from the known good bootable CF to the new 20G filesystem
cd /rmdisk/cf
find . | cpio -pudmv /export/home/mnt
Compare disk usage between source and target
cd /export/home/mnt
du -sk
cd /rmdisk/cf
du -sk
Unmount the 20G filesystem
cd /
umount /export/home/mnt
Remove the 20G loopback filesystem block device
lofiadm -d /dev/lofi/1
Copy the 20G file to a Windows media duplication PC using SFTP.
Copy the 20G file to a new blank CF on the Windows machine using dd for Windows.
dd if=C:\20G of=\\.\Voume{<VOL_NUM>}
Attempt to boot the CF in a Sun CP3260 (sparc)
boot cf
Where the devalias cf is the hardware path to the CF...
Which returns:
Bad magic number in disk label
Can't open disk label package.
Error: boot-read failed.
Can't open boot device.
Any ideas?
Format?
fmthard?
This is a file so it doesn't show up with the format command...
Edited by: BrianJester on May 6, 2010 1:03 PM
Edited by: BrianJester on May 6, 2010 1:03 PM

For downloading in UTF-8 format i wrote the code like this...
UTF ------------> with BOM
    CL_ABAP_FILE_UTILITIES=>CREATE_UTF8_FILE_WITH_BOM( IMP_PATHEXTERN ).
    OPEN DATASET IMP_PATHEXTERN
             FOR update             
        MESSAGE L_MSG 
              IN TEXT MODE
              ENCODING UTF-8
             at position 3
     REPLACEMENT CHARACTER TEXT-002  
        IGNORING CONVERSION ERRORS.
then i opened the file using noeditor ..i showed me that the file is in UTF-8 format
For downloading in UTF-8N format i wrote the code like this...
*for UTF-8N
UTF-8N ------------> without BOM
    OPEN DATASET IMP_PATHEXTERN
             FOR update              
         MESSAGE L_MSG     
              IN TEXT MODE
              ENCODING UTF-8
     REPLACEMENT CHARACTER TEXT-002  
        IGNORING CONVERSION ERRORS.
but when i opened this file using noeditor it showed SHIFTJis
So i want the code to upload/download in UTF-8N format

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