Hi!

> 1) new disk was used with Linux, but a first primary partition was made
> but never formated

Make sure it is flagged as fat32 and as lba. Check possible
messages from initdisk early during freedos boot as well.

I recently tried making a DOS bootable partition on a new
disk, too, and found: 1. I had to mimick a "fdisk /mbr"
to make anything boot 2. I had to say my partition is LBA
and bootable. 3. I had to tell sys-freedos-linux that the
disk and offset are 255 (auto) and 63 (see fdisk -u -l in
Linux) respectively as mkdosfs had failed to set those. I
also told sys-freedos-linux to use LBA style boot sectors
to avoid any geometry troubles but that was optional :-).

> 2) booted FreeDOS 1.0, and with fdisk deleted everything and creared
> only one primary partition for the whole disk

Why did you delete the partition and make a new one again?
Same bugfix suggestions as for step 1.

> 3) rebooted
> 4) fdisk /mbr (to remove grub)
> 5) format c: /s /u

Try without /s. Use the /d option to get debugging messages.
Use the combination /q /u unless you insist on waiting for
days until format completes. Really. So: FORMAT C: /Q /U /D

> I get this message:
> FATAL: Cliuster size is not 0.5, 1, 2, 4, 8, 8, 16, 32,
> or 64k but 0.0k. [Error 58]

This means the kernel did not suggest any cluster size for
that partition. Maybe it is the wrong FAT type for the size.
See the suggestions for step 1. And make sure you use a
recent kernel, for example http://rugxulo.googlepages.com/
(kernel from disk one of the distro there for example) :-).

Eric


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