I hear about other computer shops that sells customers recovery disks that they have created. I'm assuming all that they do is make a image and uses an automation script that allows this to be done.

I have seen where clonezilla does this, but it has to be the same HDD size or they might have problems down the road.

Is there any other freeware that I could do this with that allows you to use on any size disk.

Ghost is really good for this because it automatically fills up empty space with the partition and never needs any user input or "Expert Mode" like clonezilla. But it is not freeware.