FAT32 file size and Pioneer player dilemma

[umniy2000]

I have a Pioneer DV-420-K player and and external Iomega hard drive hooked up to it. Typically, I download movies online and watch them through HD-DVD player-TV setup.
The Pioneer supports only FAT16 and 32 file systems, not NTFS. So, I had my HD FAT32-formatted and everything works fine. The only problem is that sometimes the video .avi files come down larger than 4GB, which is the max size for FAT32. When this happens, I cannot even load them from my PC to Iomega HD. I can try converting them and changing some settings (like maybe the bit rate, the frame size, etc.), but I'm not sure if that will solve the problem. For instance, I tried AnyVideoConverter and converted one video from 704X448 to 512X384 frame size. It changed the file size from 5.44 to 4.59GB, which is still too large for FAT32. I can keep experimenting, but if somebody could give me a good advice, I'd really appreciate it.

[redwudz]

The size of the video frame doesn't have much of anything to do with the size of the file, mainly the video bitrate does. Lower the bitrate (And the quality) and you will have a smaller file.

[jagabo]

Why don't you just split the file into two parts without reencoding? It will only take a minute or two and there will be no quality loss. VirtualDub in Direct Stream Copy mode works well for that.

[umniy2000]

Why don't you just split the file into two parts without reencoding? It will only take a minute or two and there will be no quality loss. VirtualDub in Direct Stream Copy mode works well for that.

That's what did it for me. I used my free AnyVideoConverter for splitting and it did the trick.
Thanks all for the input.