Additional test results:
1.) Placing a 500 GB FAT32 (32k, GPT) partition at the end of the drive with nothing in front of it results in USB Loader GX asking to format, and then not being able to mount it. Looking at the computer shows that it converted it to MBR, but the 500 GB partition remained intact.
2.) Placing a 500 GB NTFS (32k, GPT) partition resulted in something I never saw it do before: It reported "2047.75 GB free of 2047.75 GB" and displays 0 games on the list. It was able to rip games and play them without any problems, but when looking at it in the computer the data isn't anywhere. It seemed to end up in the unallocated space somehow.
It is important to keep in mind that with the results of this test no games appeared at all, whereas in the previous test that worked beyond the 2 TB mark the games before and after the 2 TB mark showed up along with the game ripped from the Wii and that the data showed up when plugged back into the computer. Also in that test it successfully showed the partition size accurately so it's not like this happened specifically because data existed beyond the 2 TB mark.
3.) Deleting everything I created a new 500 GB partition (NTFS, 32k, GPT, no GPT reserved partition) after 1 TB of unallocated space at the beginning of the drive. Then I placed a single Wii game on that partition. The result was similar to the above. USB Loader GX did load, but it displayed 0 games. This time when attempting to rip "Lost in Shadow" it had an error writing path.
In other words, USB Loader GX can't handle having unallocated space at the beginning of the drive - even if the partition is completely within the 2 TB mark.
4.) Two NTFS partitions (first 1.99 TB, second 1.63 TB) resulted in "Exception (DSI) Occurred!" error, but when looking at it later it looked like there was a weird less than 1 MB space at the beginning and end of the drive unallocated so I suspected that to have been the cause, but after trying again without those the same error appeared. It seems like there are just a few formatting combinations that doesn't work very well.
5.) To confirm, I created Two NTFS partitions (GPT, 32k, no GPT reserved partition) of 750 GB each at the beginning of the drive and left the rest unallocated. I placed a single game on each partition and both loaded which verified that the issue of multiple partitions only exists when a second partition is placed beyond the 2 TB mark. One partition will work with data beyond 2 TB, but there is an issue with multiple partitions.
6.) To further verify the previous results I added a third partition - this time 1 TB - and placed a single game on it such that no data exists beyond the 2 TB mark, but that partition information exist beyond it. The result was another "Exception (DSI) occurred!", but when I resize that third partition down to 400 GB so that it ends before the 2 TB mark the third partition shows up without any problems and all 3 games work perfectly.
In other words, it doesn't seem to matter if the data is beyond the 2 TB mark at all. It was the size of the third partition that caused problems - not the sector location of it's data.
7.) Deleting all partitions, converting to MBR, and then creating a single 2 TB FAT32 partition then copying a single GC and Wii game on the partition resulted in a
successful test of both Wii and Gamecube games.
After a quick Google it seems the maximum capacity for a FAT32 file system is 8 TB. So you're fine within that area.
Do you know of a good program that will work? Both MiniTools and EaseUS limits me to 2 TB for FAT32, and "FAT32 GUI Formatter" doesn't like 512 byte drives. With a 4k drive I have no problems formatting 4 TB to FAT32, but I have yet to find a program that will format a 512 byte drive to FAT32 beyond 2 TB. I don't see why it shouldn't be possible, but the issue is finding something that will do it.
EDIT: I found "Verbatum FAT32 tool" and it did format the entire drive (or so it says), but Windows 7 doesn't recognize it. It sees it as "other". Fortunately VMware running Ubuntu could see it, but unfortunately it lags horribly trying to view it so I am thinking it was a bad format job.
EDIT 2: Another FAT32Formatter found
here was promising, but it also failed to format the entire drive. It will say it completed successfully, then spit out errors and the end result is a 1.63 TB FAT32 partition with a 64k cluster size.
EDIT 3: Also tried Swissknife, but it won't even see more than 2 TB.
EDIT 4: Seagate DiscWizard is also unable to format beyond 2 TB, but it has an interesting thing for MBR discs called "Disc Extender" to have more than 2 TB viewable in MBR for 512 byte discs, but of course it gave me an error when trying to use it. Besides that, it formatted to 64k... and I have run out of ideas for programs to try.
My advice is to format the drive (quick or full, doesn't matter) then partition is to the specifications of DIOS MIOS' launcher. The only thing that might be stopping the loader is the drive's priority. In that case make sure whatever partition manager you're utilizing that you set the FAT32 partition as the PRIMARY drive and you should be good to go. Just double check the files/folders of the launcher are all correct and you're golden.
Oh, I always make sure to set it to Primary and 32k.
I also highly recommend Configurable USB Loader. I feel it's the best available, and has a beautiful UI.
I haven't checked out that loader yet.
EDIT 5:
8.) When formatting the first partition to FAT32 (2 TB, 32k, GPT) and the second partition to FAT32 and loading one game on each partition USB Loader GX only sees the first partition, but when changing the second partition to NTFS I get a "Exception (DSI) Occurred!" so
It seems that so far the only configuration that seems to work beyond 2 TB is a single 3.7 TB NTFS partition. Unless DIOS MIOS can be made to support NTFS, or unless I can get a single FAT32 partition to be larger than 2 TB, even Hybrid mode won't be enough
