XPS 8940, creating Recovery USB for Windows 11

I originally used the Dell OS recovery tool, which created the 2 partition USB with not apparent OS image anywhere. I did that process twice and both times it only created a 2GB boot and left the rest blank. 

But Now I'm doing  a windows 11 following the techrepublic article you linked to. it is creating a 32GB booting USB with system files.

I also downloaded the OS11 image from microsoft but have not done anything with yet.

My current plan is to replace the 512GB M.2 that came with my 8940 with a Samsung 980 1TB or an 970 EVO+ as the later is Gen 3 and the 8940 only supports Gen 3.

Did you follow the steps listed at techrepublic here? Also did you want a Recovery drive or a Windows 11 installation drive. Since you referred to a Windows 11 image I suspect you want this page at MS. And using the media creation tool, it will create a Windows 11 installation flash drive.

OK to clone the 512GB m.2 I need to get a SSD USB adapter or PCIe x4 slot card

https://www.amazon.ca/Rivo-PCI-Adapter-Card-Supports/dp/B01N09W21D

Was thinking of using this so that can install the other m.2 (Samsung 970 EVO as an extra storage drive)

I have a Nvidia Card RTX 3060 that might have issues with cooling if the PCIe x4 card is not low profile so not sure if it would be just better to use an USB m.2 adapter.

I bought a Cheap NVME M.2 Expansion Card PSM2 by Orico

When I connect the 980 Pro PCIe 4.0 NVMe M.2 SSD to it and put in the the XPS 8940 Bottom slot. The Computer does not get past POSTit seems to freeze at the DELL Start LOGO.

When I remove the Card the computer boots normally and all is well.

I have set the BIOS to AHCI already , following one of your other posts here.

When I remove the 980 Pro from the card and insert the blank card into the system it boots fine. As a matter of fact I am now typing this on my Dell XPS 8940 with the bank card installed (no 980 Pro)

I read in a research that talks about 28 PCIe lanes and I'm thinking I don't have enough of them. The 980 PRO uses more lanes then the 970 EVO Plus, should could it be an issue with not enough.

Would it help if I removed my Nvidia RTX 3060 and run the XPS on motherboard Video to do the cloning of the 512GB to the New NVMe 1TB

You should re-configure to use AHCI, before you do anything else. If you don't follow this method, PC will become unbootable:

1. Open Cmd prompt window, run as administrator
2. Copy-paste this command, which will start Windows in Safe Mode the next time you reboot: bcdedit /set {current} safeboot minimal and press Enter
3. Restart the computer and tap F2 to enter BIOS setup
4. Change SATA Operation mode from RAID to AHCI
5. Save the change and exit Setup; Windows will automatically boot in Safe Mode
6. Open Cmd again, as in step #1
7. Copy-paste this command, which will start Windows in Normal Mode the next time you reboot: bcdedit /deletevalue {current} safeboot and press Enter
8. Reboot and Windows will automatically start with AHCI drivers enabled

Now you're ready to image the SSD.

You don't need a PCI-e card to do this if you have an internal HDD or an external USB HDD. Image the entire SSD and save the image on the HDD. (Use Macrium's Max compression setting to reduce space needed on HDD, and select the option to validate the image as soon as it's created). Also use Macrium to create the bootable USB you'll need in next step.

After creating the image, swap in the new SSD and set the old one safely aside. Plug Macrium USB into PC with power off. Power on and tap F12 to open the menu. Select the option to boot from USB. Macrium will load and allow you to transfer the image from the HDD onto the new SSD. Since the new SSD is larger, you'll have to move all partitions, except C: onto the new SSD first. Then move C: last and use Macrium to expand its size to use all remaining space. Only the last partition moved can be expanded, so be sure you understand the process before you begin.

When that's done, power off, remove the USB stick and boot normally. PC should boot directly from new SSD.

It worked however I some how messed up the transfer of all the partitions.

Not sure if I need to start again and figure out why it did not copy the recovery partitions and other parts

It now has only 2 partitions, The OLD m.2 SSD benchmarks and the New Samsung 980 Pro

1. Original M.2 SSD Benchmarks

2. Samsung 980 Pro Benchmark

This is the OLD M.2 SSD Partition table as seen in Macrium

No idea why the other partitions didn't get copied onto new SSD. But if PC is working ok, I'd leave it alone, especially since new SSD is marked "healthy" and giving a really nice speed increase over the other one.

WOW!  After struggling and failing with Dell Recovery and Restore (aimed at Windows 7, 8.1 and 10), the write-up on TechRepublic cited by JOcean was sooooo easy.  Didn't realize Win11 had the Recovery and Restore all pck'ed up and ready to go - all I had to do was type 'create a recovery drive in the search window and the rest is on cruise control.  Thanks!

Thanks, JOcean.  Great advice.  I followed the instructions on Techrepublic--super easy.  And now I'm reassured that I can recover Windows if needed.  I have good backups of all data--local and cloud.

Happy we could help out!