Can't write to external hard drive, kills MacBook Pro

I got a SimpleTech SimpleDrive 1TB for an external drive. It's formatted for PC but I was able to format it for Mac with no problem and read and write small files to/from it. But data that is larger than 80-90MB will not work—at that point the progress bar ceases and will not close. I can force-quit Finder but Finder will not reboot and at that point I can only kill the power. The Finder has also hung when opening a folder on this drive. After reboot the drive does not mount and I have to turn its power off and on for it to appear.
I did try to zero out the drive but aborted that after 3 hours. I figured that would have zeroed out anything on the drive but it changed nothing. What should I try next?
Jeremy

Yes, I formatted it as OS Extended (Journaled).
Overnight I let Disk Utility run and zero out the entire drive. It took 10 hours and at the end it then prepared to erase but had another error: Input/Output Error. It now appears the drive has reverted to the factory defaults (MS-DOS (FAT) format, Master Boot Record) and is unusable. I am going to return it.
Jeremy

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