The HP Usb formatting tool can make bootable fat32 partitions, and over 30gb (sksapps has it), or you can use one of the ps2 usb hard drive for matters, then use the commandline tool "bootsect.exe" from the boot folder on the vista installation dvd, to add either an xp (/nt52) or vista (/nt60) bootsector. XP bootable partition must also contain boot.ini, ntdetect.com, and ntldr, to work.
I found a wonderful vista boot editor called eazybcd, that is a good thing to have, if you like the vista bootmonger.
Not much else to say about that, all of those work on fat partitions, the ps2 doesnt care about the 30gb limit, so getting that irregular size in a fat32, then add a boot sector.
Note on the hp tool will reformat your device, the bootsect tool, will not, it repairs or adds a bootsector without formatting your drive.
Bootsectors can also be hexed in, with winhex, or other brute force hexer, but bootsect is the best way I know of. I cant post it, sicne its microsuck, but it's in the boot folder of every vista installation dvd.
A toxic agent on a dangerous mission so secret, even I don't know what it is, because if I did, I would have to kill myself. I don't even know who's side I am on.