Just fyi i have updated the wiki article with some a second method for those who are lazy :)
Got a 16gig stick, but all thats on mine at the moment is some photos of my daughter, NOD32 antivirus and a complete copy of Medieval Total War 2 :)
Loads of portable apps, few random bits of multimedia stuff, application setups, symantec antivirus corp 10, random downloads of web things; and a separate one with bootable Knoppix :)
I can't remember exactly which one I used but these seem vaguely familiar:
I'll be here all week... :D
Puppy Linux comes with a usb installer that's pretty nifty - you can customize grub to boot to other things too - also works well on usb hard drives - useful for ghost images ;)
Portable Apps menu with not much original stuff - all sysinternals tools plus anything biggish that's quicker to have on me that d/l across the n/w.