There seems to be a limitation on how large Windows 7 (and probably Vista) will let you format a partition as FAT32. I had a 320gb USB drive I needed to format as FAT32 so I could plug it into the XBOX 360 from which to watch some videos. Windows 7 only gave me the option of exFAT, which isn't widely supported yet, and NTFS, which the 360 doesn't support. I believe this happens if the drive is larger than 32gb. Trying it from the command line gave me the option, but still ultimately failed. I'm sure someone with better googling skills than me could find this information out quite quickly and easily, but it took me a few minutes to figure out so here we are. If you find yourself in the same boat, try a free app called "FAT32Format". I found a GUI version here. It works in 64bit Windows 7 et al and doesn't require an install. The file seems a bit suspicious, but I submitted it to VirusTotal and all came back clean.
