What it might be is that XP won't allow you to format a drive bigger than 32 Gb with FAT32, so you'll need to partition it. If you use a C: drive partition of 8192 Mb the formatting will come out at 4096 bytes per allocation unit in BOTH FAT32 & NTFS.
My 80 Gb drive has four partitions, 10237, 10237, 20481 and the rest, 37197 Mb
All are now formatted to NTFS.
If you want the easy repairability of FAT32 what some do is to format the C: drive to FAT32 and the bigger drives to NTFS.
I make a drive image of Drive C: , the Operating System drive so restoring is just a matter of restoring from CDRs.
The restore operation removes all data from the C: drive so the restore is clean.
I use Image for Windows to make the images and Image for DOS to do the restoring.
If you get BootIT NG from TeraByte Unlimited you get both of these programs, a boot manager, which will allow you to make more than four partitions, and a partition resizer.
Four programs for US$60. $15 a piece.