Formatting a USB drive HOWTO  
First partition the usb using the fdisk utility as root:
fdisk /dev/sdb
using fdisk, add a partition of type FAT16. When printing the partitions using the 'p' key, you should see:
Device     Boot Start      End  Sectors  Size Id Type
/dev/sdb1        2048 15826943 15824896  7.6G  6 FAT16
Then write the partition table to the disk and exit. Then format the partition to vfat using the command (as root):
mkfs -t vfat  /dev/sdb1
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