Hi,
Yes, use 512MB as the media size as the factory image will expand to fill the available space.
Check the inetpub/ftproot/Rapport/tools/sa/9455 and make sure all the files are there (about 7 files) – I have seen WSI install and not put the files in.
Also in the push.i2c there is a line =yes change it to =no
The not found can come from to tools files missing, the 9455.i2d file missing/wrong name or the flash on the unit not found (wrong slot or broken)
Cheers,
-TT