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Some formats have a max size..for instance, FAT's max size might be 2 or 3 gigs..I don't remember, can anyone clarify this?
You say "FAT" but which FAT? if it is FAT16, I could well understand you being forced to format? I believe that FAT16 will support 2GB in theory, although many BIOSES of the day did not (there was a barrier at 1.97GB). This is for DOS, Win 3x and early Win95. NT would support 4Gb, but only if you used 64KB clusters, which would cause problems with the other OSes. Later versions of Win95, along with 98 & Me used FAT32, which does not have this problem.