Hacking sd card format? (ez-flash Vi)

[Zarxrax]

I was previously using a 1gb microsd card, and everything worked fine. I don't remember how it was formatted though.

Yesterday I got a 4gb card, and at first tried formatting as fat16. That didn't work though, because the cluster size was too big or something. Windows wouldn't let me adjust the cluster size for fat-16, so I tried doing fat32. I think I used 32kb cluster size.
Now, some of my roms run just fine, but for others I get a read error when trying to launch them. I'm thinking this has something to do with how I formatted the card.
Whats the correct way that I should format this?

 

[Zarxrax]

After some trial and error, I have solved the problem.
It turns out that I had formatted my card with the default settings (FAT32, 4096B cluster size) and this was causing all kinds of errors.
When I reformatted as FAT32 and made sure to set the cluster size to 32kb, everything began working.