well, as a couple of notes, FAT32 cannot, in fact, have a partition more than 32GB.

as far as making the partitions, what kind of partition were you trying to make? primary, extended, or what? you can have up to four primary partitions, and one extended.

maybe you should try configuring the partitions manually at the beginning, rather than let the machine do it for you... we all know just how faulty these things can get.

otherwise, i haven't got that many ideas, sorry