Have you considered keeping a Knoppix CD around as a rescue CD? That'll give you enough tools to boot the PC and a working command-line from which you can run Linux's FDISK and mkfs, both of which will create and format FAT16 and FAT32 partitions. After that you can use Unix tar to copy the entire directory tree from one disk to another.
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Date: 2008-01-25 06:05 pm (UTC)