If you have been using Disk Utiltiy to create the USB thumb of the InstallESD.DMG file then yes I had problems using DU to make it. I then found LionDiskMaker which is a small program specifically written to create either a DVD or thumb drive of the Lion install files. Works great and have not had any failures in creating the thumbs.
Yes I've been using my only MBP which is a late 2011 model that came with Lion. I've gotten the Lion install files several ways. Bootint to the R-HD and downloading to an external then disconnecting that external when the system want to Auto reboot. Using the USB thumb of the R-HD files I created with Lion recovery disk assistant then the same as above. Then I used this hint to actually load and run the Recovery HD program while I was actively booted into Lion. I found this one the easiest as it give you a chance to save the files while your are running the computer.
10.7: How to get a full Lion install disc for a new MacBook Air or Pro - Mac OS X Hints
Try LionDiskMaker, Google search.