On 800x480 Evo, if the source is 16x9, it indeed goes full-screen. Simple hacks have been out for some time to partition the SD card and make at least a part of it an ext filesystem (hacks are really just instructions). Don't recall if that changes max file size. Most of those were to offload a part of the OS to the SD card - I tried that for a short while last year when tinkering, don't recall what I was I up to at the time, but I went back to stock. (I think I went down that path as part of a kernel tryout.) You could use it as a workaround to get your apps on the SD card, also (that was pre-Froyo). I've seen that mentioned on Sammies, haven't been able to converse with anyone to get a clear explanation on what's up with their phones. I've been under the impression that you always needed a FAT32 partition as primary with Android. Have not heard of anyone using NTFS. I don't think anyone's of the illusion that FAT32 is ideal, just universal.