Formatting the FAT32 Partition of the Wii HDD
1. To format a FAT32 partition on the Wii HDD, return to the the PC Disk Manager and again either select the size of partition for the FAT32 format or select all the remaining space. The process is the same as directed under the Partitioning the HDD section. Right click the Wii HDD and again select New. Assign a letter to the new partition. This time, select Format when creating the new partition. Format as FAT32. If choosing a cluster size, choose 32KB to be consistent with the size of the Wii disc sector.
2. In the event of an error such as "The volume is too big for FAT32" there are several options to try to successfully format the selected partition as FAT32:
2A. DOS Command - use the DOS command: in WinXP Go to Start, then RUN, then type CMD. In Win7 Go to Start, use the search window and enter cmd, select it when found.
At the prompt, type format /FS:FAT32 X: ; substitute the letter of your designated Wii Drive FAT32 partition for the letter X.
2B. The DOS command will not work for HDDs 1TB and larger. Try one of these FAT32 formatting tools from either Ridgecrop Consultants HERE or the Tokiwa FAT32 formatter HERE.
2C. Or try Easeus Partition Manager. This is also a good hard drive utility for creation of multiple partitions (FAT32 and NTFS) or if the FAT32/NTFS partitions require resizing after creation. Download from HERE.
3. To use the Wii HDD FAT32 instead of the SD card, the files and folder structures must match that of the SD card.
Example: HDD:\Apps\Wad Manager\boot.dol
The Homebrew Channel will first look at the SD card slot, if no SD card is resident, then HBC will look at the FAT32-formatted HDD partition. Remember that many, but not all, homebrew applications will run from the HDD.