FAT32format is a small, simple and powerful application that canformat large hard disks in FAT32, even in Windows XP.
Just partition the drive, then type "fat32format X:" where X is the partition letter.
It is also possible to set the cluster size with a -cN parameter where N is the number of sectors per cluster. On a hard disk, which is the only sort we support, one sector is 512 bytes. The cluster size will be N times 512.
It seems that Windows XP supports small cluster sizes, except that chkdsk runs very slowly, presumably because it needs to read the huge FAT that results from these settings. Given the nature of FAT32, you can't reduce the cluster size such that the number of clusters is more than 228.
