Create a Kali Live USB in the Same Pendrive You Use for Data

I have only 1 pendrive of 16 GB. So I am going to create 3 types of partitions in it so that I can use my pendrive as a normal data traveler + Linux security toolbox which I can bring anywhere easily.

10 GB of NTFS for normal day to day use as the data traveler
3 GB of FAT32 to install Kali Linx
1.5 GB of ext4 to persistence use

If you don't want your pendrive to use as a data traveler, you need to create 2 types of partitions only. Which are the FAT32 one & the ext4 one. Since it is a 16 GB pendrive it is a waste of doing so.

Download Mini Partition Wizard from here.

Open Mini Partition Wizard. The 1st look will be like the following.
(click on the image to see the full size)

My pendrive is empty and it has a default NTFS partition.

Creating the 10 GB NTFS Partition as a Data Traveler

Right click on your pendrive & select Move/Resize

Give these settings & hit ok

Creating a 3 GB FAT32 Partition for Kali Linux

Right click on unallocated space & select create & click yes

Give these settings as in the screen shot and hit ok

Creating a 1.5 GB ext4 Partition for Persistence

Right click on unallocated space & select create & click yes

Give these settings as in the screen shot and hit ok

Now everything will be like this.

Now all the partitions have been created. Let's apply the changes now.

After applying the changes you may see that the drive letter D: of the FAT32 partition is gone. So without a letter Windows will not identify the partition. So we have to do some changes to make it work form here.

1st delete the NTFS partition & give a letter to the FAT32 partition & hit Apply.

Now It will be like the following.

In My Computer the drive will look like the following.

Installing Kali

Download Kali ISO from their website. I downloaded the 32-bit full version of 2.6 GBs wich is compatible with most computers.

Now download Universal USB Installer from here

Open it, Select the ISO file and other parameters like this capture and hit create.

Wait for few minutes till it completes its job.

Now go to Mini Partition Wizard again & right click on FAT32 partition & select change letter & select none. Right click on the FAT32 partition again and select set active. It is used to identify the partition with the OS boot files when you boot from the pendrive later.

Right click on unallocated space & select create & click yes
Give these settings as in the screen shot and hit ok

Now everything will be like following.

Booting Kali from Pendrive

Now it's the time to reboot the PC and select USB drive in boot options.

Choose the option "Live USB Persistence"

Now don't click on the "persistence" icon on the screen.

Go to terminal and enter the following commands

Make a directory on the filesystem to mount your USB
mkdir -p /mnt/usb

To findout which partition of your drive you'll use (for mine it's sdb3)
fdisk -l

Mount the partition on the directory you made
mount /dev/sdb3 /mnt/usb

Add a configuration file to enable persistence

echo "/ union" > /mnt/usb/persistence.conf

Unmount the partition and reboot

umount /dev/sdb3 && reboot

After the reboot select USB drive in boot options & again choose the option "Live USB Persistence"

From now onward every config you do will be saved and it's more like using a dedicated Linux box.

Also you have your 10 GB pendrive for day to day use as a data traveler. cheers..!!