use the command prompt format command not the GUI version built into windows. you will get more control over things like cluster size.
-another world
C:\format /?
Formats a disk for use with Windows XP.
FORMAT volume [/FS:file-system] [/V:label] [/Q] [/A:size] [/C] [/X]
FORMAT volume [/V:label] [/Q] [/F:size]
FORMAT volume [/V:label] [/Q] [/T:tracks /N:sectors]
FORMAT volume [/V:label] [/Q]
FORMAT volume [/Q]
volume Specifies the drive letter (followed by a colon),
mount point, or volume name.
/FS:filesystem Specifies the type of the file system (FAT, FAT32, or NTFS).
/V:label Specifies the volume label.
/Q Performs a quick format.
/C NTFS only: Files created on the new volume will be compressed
by default.
/X Forces the volume to dismount first if necessary. All opened
handles to the volume would no longer be valid.
/A:size Overrides the default allocation unit size. Default settings
are strongly recommended for general use.
NTFS supports 512, 1024, 2048, 4096, 8192, 16K, 32K, 64K.
FAT supports 512, 1024, 2048, 4096, 8192, 16K, 32K, 64K,
(128K, 256K for sector size > 512 bytes).
FAT32 supports 512, 1024, 2048, 4096, 8192, 16K, 32K, 64K,
(128K, 256K for sector size > 512 bytes).
Note that the FAT and FAT32 files systems impose the
following restrictions on the number of clusters on a volume:
FAT: Number of clusters