Yeah, I reformatted it a few times doesn't fix the problem unfortunately. I guess I'm going to have to replace the hard drive.
It would really help if you told us exactly what you have done so far ..
You say you 're-formatted' several times - Yes, but HOW ??
You cannot format a volume larger than 32 gigabytes (GB) in size using the FAT32 file system during the Windows XP installation process. Windows XP can mount and support FAT32 volumes larger than 32 GB (subject to the other limits), but you cannot create a FAT32 volume larger than 32 GB by using the Format tool during Setup. If you need to format a volume that is larger than 32 GB, use the NTFS file system to format it. Another option is to start from a Microsoft Windows 98 or Microsoft Windows Millennium Edition (Me) Startup disk and use the Format tool included on the disk.
http://support.microsoft.com/kb/314463
(Ignore the 'during Setup' .. This is a global, artificial, M$-imposed limit )
So.. You say you have windblows ...
Did you format the volume under windblows or ..

See the problem here ?
You do not provide enough information to really help you .
(You need to do EXACTLY as stated on the emCore-site !)