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I downloaded the latest pfSense ISO (pfSense-2.0.1-RELEASE-i386.iso.gz) and had 7zip extract it, but it just shows me the disk contents. I cannot extract the actual ISO file to burn it with the boot sector properly in place. What am I doing wrong?

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7zip is most likely gunzipping the compressed file, and then opening the iso for you.

The best bet is to gunzip the file with gunzip:

$ gunzip pfSense-2.0.1-RELEASE-i386.iso.gz

This should result in a file called pfSense-2.0.1-RELEASE-i386.iso that is the iso itself.

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