The idea is to create partitions on target windows system and than format them on OS X.
You should be root and very carefull in terminal window on OS X.
1. Create two partitions in Windows (w2k in my case), first for HFS+, second for FAT32. No need to format them.
2. Connect drive to OS X. Befor switching drive on run this command from terminal
ls /dev/rdisk?
, you'll get list of current disks.
3. Switch on ext. drive. If OS X pop up with window about initing new drive press ignore.
4. Repeat last command. Now you should see one more disk in the list. Remeber it's number (f.e. 2).
5. Make
ls /dev/rdisk2*
You should get rdisk2s1 and rdisk2s2 - first is first partition, second is second.
6. Run command
newfs_hfs -v VOLUME_NAME /dev/rdisk2s1
When it's done you have HFS+ partition.
7. Run command
newfs_msdos -v FAT_VOLUME_NAME -F 32 /dev/rdisk2s2
Now you have FAT32. It's not limited by 32G - I have 100G and it works at least with OS X 10.2.6.
7. Powercycle ext. drive.
8. In my case OS X picks up FAT32 partition, but doesn't recognize HFS+ (what an irony . Type
hdid /dev/disk2s1
and it will mount and show icon on display. Pay attention - this time it's not rdisk2s1, but disk2s1.
9. On Windows go to disk manager and assign some letter to FAT32 drive. W2K works fine with partitions >32G, just doesn't want to create them.
This is it.