http://en.wikipedia.org/wiki/File_Allocation_Table
Max. volume size FAT16: 2 GB (4 GB for 64 KB clusters)
For my experiments, I have a 1GB USB stick for FAT16 testing.
That way, the tools don't complain.
This is what I use, if the experiment will involve FAT16. Hard
to say, whether anything like this for sale today, is a legit 1GB
stick or not. Flash seems to start at around 8GB or so now.
http://www.amazon.com/Kingston-Trav...=1361650125&sr=8-2&keywords=datatraveller+1gb
Based on my experiments with Bart, I was pretty happy to just
use the CD option. As that worked. To avoid a barrel of
wasted CDs, you load them into VirtualPC 2007, and test that
they boot and do what they're supposed to do. That way, I
only needed to "waste" one CD, to get where I wanted to go.
Also, I vaguely remember doing that experiment you're trying,
and I think the Bart solution only works with a particular
flavor of FAT. And the code is not clever enough to look at
the volume, and say "your volume is FAT32, and this tool
cannot handle FAT32". Instead, the Bart solution just
corrupts the volume. So if you really think that method
is going to work, you'll need to feed it the FAT16 it is
looking for. And, that's where the small USB stick comes in.
I think I tried various methods, to make a larger stick
handle a smaller file system. One trick, for example, is
prepare FAT16 on a 1GB stick, then use "dd.exe" to image
the stick and copy it to an 8GB stick. That fools the
tools into thinking everything is OK. It's one way to get
FAT16 onto an 8GB stick (with space left over at the end
which cannot be accessed).
I did a ton of experiments, with nothing working to show
for my efforts. I don't remember all the permutations
and combinations I tried at the time. It's just a blur now.
Paul