the maximum partition size for FAT32 is 32GB (well, maybe it's 30GB. i might be off by a bit).

as Trust_Not_123 said, Partition Magic would be a great tool to use in this situation. the Disk Management MMC Snap-In in Windows 2000 or Windows XP could also be useful, but you could only access those if you're installing that o/s, which i'm not entirely sure if you'd be up to doing. either of these tools are relatively easy to use, with a simple GUI.