FAT32format 1.04

You cannot format a volume larger than 32 gigabytes (GB) in size using the FAT32 file system during the Windows XP installation process. Windows XP can mount and support FAT32 volumes larger than 32 GB (subject to the other limits), but you cannot create a FAT32 volume larger than 32 GB by using the Format tool during Setup. If you need to format a volume that is larger than 32 GB, use the NTFS file system to format it. Another option is to start from a Microsoft Windows 98 or Microsoft Windows Millennium Edition (Me) Startup disk and use the Format tool included on the disk.
Actually, looking back at the Microsoft comment, if I could format the volume myself, all would be OK. Fat32 is pretty simple, so it occured to me to write a fast format routine to do the job. Note that the 32GB limit is a limit of the formatter in Windows XP. FAT32 itselft should be OK to 2TB, limited by a 32 bit sector count in the boot sector. XP comes with a partitioning tool, called Disk Management. It even has Wizards for partitoning. This should be a cinch.
Ive tested this with a SATA disk as follows. Power off the computer and connect the disk. Power up again - check the Bios finds it. If you have a IDE or SATA disk, make sure you power off before connecting, USB and Firewire ones can be connected with the power on.
Theres a guide on Disk Management here You need to find the disk with unallocated space. Right click on it and select "New Partition" and follow these steps, clicking "Next" to get move on at each stage.
1.Partition Wizard starts, just click next to move on
2.Select Primary Partition.
3.Enter the maximum size for the Partition Size
4.Choose assign a drive letter. I used F:
5.Select "Do not Format this partition"
6.There will be a dialog box, summarising all the previous stuff. Click Finish
Now you have a drive letter, this is what we will pass to the formatter