FAT is not particularly robust and OS X is not forgiving to problems with FAT. Disk Utility First Aid will not repair FAT problems. I know this first hand where a friend bought a Firewire drive which was formated with FAT. Of course it worked when he plugged it in so he did not think to format it as HFS+. Some time latter an application crashed and left the drive in a bad state. In order to recover the drive I had to install a Firewire card in a PC and use PC recovery software to recover the files as best I could.

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