I need to format a 500GB external HD in FAT32. I tried using Disk Management (XP) but cannot create a partition larger than 32GB. I used the cmd line to format drive but after APPEARING to be working for over 2 hours I got a message that the drive was too big. How can I get this drive formatted. I need to move files between a Mac and a PC.Have a read of this...and this: http://support.microsoft.com/kb/314463

FTA: "You cannot format a volume larger than 32 gigabytes (GB) in size using the FAT32 file SYSTEM during the Windows XP installation process. Windows XP can mount and support FAT32 VOLUMES larger than 32 GB (subject to the other limits), but you cannot create a FAT32 volume larger than 32 GB by using the Format tool during Setup. If you need to format a volume that is larger than 32 GB, use the NTFS file system to format it. Another option is to start from a Microsoft Windows 98 or Microsoft Windows Millennium Edition (Me) Startup disk and use the Format tool included on the disk."

Best of luck.

Btw, how many bytes are you looking at? Is an online storage/transfer site an option?

It might be helpful to know the "exact" command you used to format and the "exact" error message you received.

That being said, I've never formatted a 500 GB hard drive as FAT32. I did come across this link, which may be what you've already tried:
Format Large Disks to FAT32 on Windows XP and Vista

Any reason you can't partition the 500 GB drive into smaller logical units.

If you use a Windows 98 or Windows ME Startup Disk you may encounter a disk size limit of 127 GB as they do not provide native support for 48-bit Logical Block Address (LBA). (Not sure about this... but SOUNDS about right).