I have a 80 GB video ipod that ran rockbox fine, using a FAT32 partition. I got a filesystem corruption after I installed rockbox 3.0 (may or may not be related) and I have reformatted the data partition.
However, it doesn't work, I can't seem to create a FAT32 filesystem from Linux that Rockbox can see. I tried a variety of parameters and every time I get "Can't load rockbox.ipod".
One thing I noticed is that I can't use the default sector size "512", otherwise mount fails with " kernel: FAT: logical sector size too small for device (logical sector size = 512). When I use -S 2048 Linux can mount but the bootloader doesn't find rockbox.ipod.
When I originally installed Rockbox I had a freshly initialized iPod from iTunes (wiped out, then connected to iTunes and it created the partition table and filesystem). I don't have access to that Windoze installation right now and I think there should be a way to create the right kind of FAT32 from Linux, right?
My gut feeling is that Windoze somehow manages to make a 512 bytes sector filesystem that is usable and that Linux' mkfs.vfat somehow screws this up.