IMac and Formatting USB Drive Issues

I have an 8GB USB drive that I formatted to MS-DOS FAT using my iMac with 10.6.4 on it. However I now realise that that was a stupid thing to do as now that drive no longer works on Windows no matter what I format it too. I want the pen to allow me to use it on both WIndows and Mac (hence the FAT format) however Windows sees the drive as an unformatted 200MB drive with 7.16GB of unallocated and corrupted space which cannot be formatted.
Windows cannot even attempt to allow me to format it to gain the 8GB back as it is unable to format the space even when its turned into free (empty) space. Luckily OSx can still use it as normal but it just means I've lost a perfectly work USB drive due to an error in OSx.
Can anyone help to to fix this as I really want it to work and I'm stumped as to how.
Thanks!

It shouldn't matter as I created the files and folders originally on a FAT formatted drive and copied them to my Mac then back at a later date, at which point an error was encountered and prevented me copying folders to the dive (the contents was fine once removed from folders and sub folders).
I believe Apple has fixed this now, however when I formatted the drive my iMac had this problem so I believe this effected the FAT formatted drive to prevent Windows working with it.
Well I have finally managed to fix the drive. I had to format the drive to free space and then plug it into a Windows 7 PC and then delete the free partition and reallocate it again to FAT 32. Window Vista and XP where an able to do this as they say I didn't have permission to do this and asked for a restart. Strange but atleast it finally works on both machines.

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