Idiosyncratic Capacity Problem Copying to FAT32 - Not The Usual

Here's the thing.
I'm well aware that there is a 4G file size limit when copying from a Mac to a FAT32 drive.
But I'm encountering a 4G total capacity limit. In other words, if I copy small, individual files, not even all at once, but over a period of time, to, say, a 32G flash drive, the copy process hangs and freezes as soon as I hit the 4G mark. As if I don't have 28 perfectly good, empty gig left to go.
When I bought the iMac, in late 2006, it was running Tiger and this was not a problem. The problem began when I upgraded to Leopard. And it has persisted through a recent upgrade to Snow Leopard. (Yes, I know how behind I am, but I need to hold onto Rosetta for a while. Everything else is working without a hitch.)
I tried reformattiong the drives as FAT32 freshly, via Disk Utility -- that hasn't worked either.
I've spoken to several phone techs and Apple store Geniuses; not only haven't they been able to help me, none of them has even heard of this occurring before.
At a guess, I'd say that there's some hidden protocol preventing my iMac from recognizing that there's anything more than 4G on a FAT 32 drive -- and that if I can find it, I can de-activate it. But I'm utterly without a clue as to how it got triggered (well, save that a system upgrade was the clear catalyst) or where it resides. (I suppose there may be another cause, but nothing else makes sense to me.)
I'm having no problem whatsoever with Mac formatted flash or auxiliary drives. Only FAT32.
Can anyone Out There help me solve this?

Sorry to take so long replying.
Yes, tried it and it doesn't work. (Actually, simply reformatting the drive creates a single partition by default, as displayed by the progress "narrative" in Disk Utility.)
As I say, I don't believe this has ANYTHING to do with drives or how they're formatted. I'm pretty convinced there is some hidden operational protocol ENDEMIC TO THE COMPUTER that got triggered somhow. Something that's not part of the "civilian" settings or that you can dope out by poring through the System Preference options (I'm really good at that kind of troubleshooting and I've tried). That's the only explanation that seems to explain the idiosyncrasy and its consistency.
I wonder if the answer may be some kind of override or cancel command line you might enter into Terminal. 
Anybody have a notion about something like that?

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