What can I do to increase the size of my 4GB travellers’ disk? Your software allowed me to create a 28GB travellers’ disk, but it didn’t finish the process – it froze on 4GB.

In the windows FAT file system, in which your flash disk is probably formatted is not possible to create files bigger then 4GB. You need to format your disk with NTFS system settings, which are used in your system disks and external disks. The NTFS system supports files with size of up to 15EB.