I have been having some weird issues with ps2packer.
I have put hdd support into radmenu.
With the uncompressed version everything works fine.
With the compressed version everything worked fine except hdd support.
Then I added usb support.
With the uncompressed version everything works fine.
With the compressed version everything worked fine except usb support although the hdd support still worked.
Looks like it isnt unpakcing everything correctly. I suspect it has something to do with the last part of the file.
I make excuses myself with you if I know too much insisting. sorry. unfortunately I do not know the C language and I cannot help you to fix the problem.
i'm looking for ps2 apps similar to your application for long time....