>
> I have tried fsck_msdos, the Windows disk utilities, and even Norton
> Utilities, and they all think the partition looks fine.  If I boot XP, I can
> beat on the disk for hours on end without any problems, so I don't think it's
> failing hardware.
>
> Anyone else seeing anything like that?

i've seen problems with LARGE FAT32 partitions (>>10GB) for a long time 
and i use mcopy for most of things