FAQ
TL;DR: Windows Disk Management caps FAT32 volumes at 32 GB, so a 64 GB flash drive shrinks when you create a recovery disk; "use a third-party formatter to reclaim space" [Microsoft, 2023; Elektroda, mlewan, #15306410]. Why it matters: regaining the lost 50 % keeps the stick usable in radios, consoles and PCs.
Quick Facts
• Windows’ GUI limits FAT32 volumes to 32 GB [Microsoft, 2023]
• Advertised 64 GB (decimal) ≈ 59.6 GiB displayed [Seagate, 2022]
• FAT32 single-file ceiling: 4 GB – 1 byte [Microsoft, 2023]
• exFAT volume size ceiling: 512 TB [Microsoft, 2023]
• DMDE freeware edition handles one device at no cost [DMDE, 2023]
Why did my 64 GB USB stick show only 32 GB after making a Windows 8.1 recovery drive?
The recovery-tool created a 32 GB FAT32 partition because Windows’ GUI refuses to format larger FAT32 volumes; the rest stayed unallocated, so Explorer hid it [Elektroda, Matuzalem, #15306674; Microsoft, 2023].
How can I restore the missing space with built-in Windows tools?
Open Disk Management (Win + R → diskmgmt.msc). Delete the 32 GB partition, then create a new 64 GB volume and format it as exFAT or NTFS. This works only if “Delete Volume” is clickable; many sticks show it greyed out [Elektroda, delphin78, post #15307063]
Disk Management greys out “New Simple Volume” — what now?
Windows classifies most USB sticks as removable. Removable media block multi-partition commands. Use DMDE, Rufus or USB Disk Storage Format Tool, which bypass that limitation [Elektroda, mati211p, post #15307234]
What is DMDE and how do I merge partitions with it?
DMDE is a disk editor. 1. Select the flash drive. 2. Delete existing partitions. 3. Create one unformatted 64 GB entry, apply, reconnect, then format in Windows [Elektroda, mati211p, post #15307695]
Can I safely delete the recovery partition?
Yes; removing it only erases the recovery files on the stick, not the PC’s internal recovery. Keep another recovery medium before deleting if you lack installation media [Microsoft, 2023].
Why does Windows report 61.9 GB instead of 64 GB?
Manufacturers use decimal gigabytes. Windows shows binary gibibytes. 64 GB ÷ 1.073 ≈ 59.6 GiB; 61.9 GB appears when formatted due to file-system overhead [Elektroda, mati211p, post #15308126]
Should I format the drive as FAT32, NTFS, or exFAT?
Choose FAT32 for maximum compatibility, NTFS for files >4 GB with Windows devices, exFAT for large files on modern TVs, Macs and cars built after 2014 [Microsoft, 2023].
Windows only offers exFAT/NTFS — how do I force FAT32 on 64 GB?
Run USB Disk Storage Format Tool, tick “FAT32”, full-format the stick. The utility bypasses the 32 GB FAT32 limit [Elektroda, pidar, post #15311925]
Does NTFS shorten flash-drive life?
“NTFS and TLC memory raise failure rate” [Elektroda, pidar, post #15308678] NTFS writes extra metadata, so wear increases. Lifespan drop is small on SLC/MLC sticks but noticeable on cheap TLC models [Kingston, 2022].
What file-size limits apply to each file system?
FAT32: 4 GB − 1 byte, exFAT: 16 EB, NTFS: 16 TB (practical) [Microsoft, 2023].
How do I reformat a 64 GB stick to FAT32 in three steps?
- Launch USB Disk Storage Format Tool. 2. Select device → choose “FAT32” → full format. 3. Wait until “Format complete” appears, then safely eject. Average 64 GB full format over USB 2.0 takes 35–45 min at 25 MB/s [Tom’sHardware, 2023].
Edge case: drive still shows 32 GB after formatting — why?
The stick may be a fake that reports 64 GB but contains 32 GB of real NAND. Run H2testw; if write errors appear beyond 32 GB, demand a refund [Elektroda, pidar, post #15311988]
Will my car radio or PS2 read the 64 GB drive?
Many radios and the PS2 recognise only FAT32. Format accordingly and keep partition below 32 GB if firmware is old [Sony, 2019].
Can I create multiple partitions on a USB stick?
Yes, but Windows will show only the first partition on removable media unless you alter the registry or use drive-type flipping utilities [Microsoft, 2023; Elektroda, mati211p, #15307234].
How long does a full FAT32 format of 64 GB take?
On USB 3.0 at 100 MB/s it finishes in about 11 min; on USB 2.0 at 25 MB/s expect ~45 min [Tom’sHardware, 2023].
