Okay, partitions are backed up to the NAS as .7z archives. The homebrew + emu NAND archive is ~10GB, and the disc backups archive is ~200GB.
I'm reading that the Wii likes a FAT32 partition with 32KB cluster size, and that modern Windows won't format large FAT32 partitions. The USB HDD is 500GB, so I've booted an OpenSUSE VM and mapped the USB HDD into it.
Tried GParted first, but it set a 64KB cluster size. Now I'm trying mkdosfs on the command line, with a bad sector test.
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