It is so simple. You burn the DSL ISO to a CD, boot from it and once you are booted from the Live CD there is an option to install it on a pen drive.
To do it manually you have to get a utility that will format it with a boot sector on the USB drive. HP actually has a really nice tool to do this. Once you do that you can extract the ISO to the pen drive. I have done it both ways.
You may also want to check out backtrack they have a full live cd and usb pen drive version.
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