2kevdog32
I've tested all possible card sizes (from 2 to 32 Gb) and have no problem with them (nor diskboot.bin, nor PS.fi2). May be your problem, that you're trying to use autoboot on big cards, and put "BOOTDISK" label in the wrong place (note that this label located at the different offset on fat32 (4-32Gb) than fat16 (1-2 Gb)).