Hmm...
I can't think of any free tools for DOS/Windows that can make a >32GB FAT32 partition. I know Partition Magic can do it (it's what I use most of the time) but not only is it not free, it's outrageously expensive.
If you have or can make a Linux boot disk, you can make the partition with cfdisk and then format it with (assuming it's the first or only partition on first or only IDE hard drive) mkdosfs /dev/hda1
I know I didn't help at all, but I tried. 🙂