I have run into this problem numerous times now, and I don't know what
is causing it or how to make sure it doesn't happen again.

I am using VMWare 4.5.2 Workstation to create a base OS image. I
removed the SCSI controller in the config file (caused Windows XP SP2
install to BSoD after SysPrep). I install WinXP with integrated SP2
into a 6 gig NTFS primary partition. I go through the normal setup and
that is it. No apps, Windows Updates, etc.

I run SysPrep with the following sysprep.inf, using the command:
sysprep.exe -activated -forceshutdown -reseal -mini -quiet

************************************************** ****
[Unattended]
OemSkipEula=Yes
ExtendOemPartition=1
InstallFilesPath="C:\Winxpcd\I386"
ResetSourcePath="C:\Winxpcd\I386"

[GuiUnattended]
AdminPassword="**********"
EncryptedAdminPassword=NO
OEMSkipRegional=1
OEMDuplicatorstring="Windows XP Service Pack 1 Base Image"
TimeZone=35
OemSkipWelcome=1

[UserData]
ProductID=*****-*****-*****-*****-*****
FullName="Faculty/Staff/Student"
OrgName="University of Dayton"
ComputerName=XPSP1Base

[TapiLocation]
CountryCode=1
Dialing=Tone
AreaCode=937
LongDistanceAccess="8"

[Identification]
JoinWorkgroup=UofD

[Networking]
InstallDefaultComponents=Yes

[SysPrep]
BuildMassStorageSection=Yes

[SysprepMassStorage]
************************************************** ****

I then backup the image using ZEN Imaging. I restore the image using
ZEN Imaging. If I boot into Windows PE or Bart's PE and run a "chkdsk
/r C:", I get a lot of bad clusters and MFT errors.

I believe we had this problem with ZfD 4.x. I can confirm that we are
having this problem With ZENWorks 6.5 as well now.