For anybody who is curious, here are some cluster size results of some tests I just ran through (default cluster size unless otherwise noted):
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256MB Lexar 32x
Windows XP (FAT)
4,096 bytes in each allocation unit
62,394 total allocation units on disk
Windows XP (FAT32)
2,048 bytes in each allocation unit
124,424 total allocation units on disk
Treo 680 (FAT)
4,096 bytes in each allocation unit
62,394 total allocation units on disk
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1GB Lexar
Windows XP (FAT)
16,384 bytes in each allocation unit
62,445 total allocation units on disk
Windows XP (FAT32)
4,096 bytes in each allocation unit
249,356 total allocation units on disk
Treo 680 (FAT32)
4,096 bytes in each allocation unit
249,356 total allocation units on disk
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2GB Transcend 150x
Windows XP (FAT)
32,768 bytes in each allocation unit
62,790 total allocation units on disk
Windows XP (FAT /A:32K)
32,768 bytes in each allocation unit
62,790 total allocation units on disk
Windows XP (FAT32)
4,096 bytes in each allocation unit
501,408 total allocation units on disk
Treo 680 (FAT32)
4,096 bytes in each allocation unit
501,407 total allocation units on disk
* Interesting to note that XP's default FAT format already uses 32K cluster size on a 2GB card.
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