I've got a 250 gig external USB2.0 drive that does the same thing, formats fine in windows, it even will format in OS X(if I don't do anything like zero-fill). Whenever I add data to it, however, it will get to some arbitrary point, such as 1.2 gig out of 11 or 30 megs out of 100, and then lock up the entire machine, with the only ways to recover being a manual power-down of the machine, or flipping the power switch on the drive. Called MacMall, the ones who sold it to me, and they had me boot with my OS X DVD and format from there. It sort of worked for a while, as in I was able to get my 11 gig music folder over, but now I can't get it back off without taking small chunks at a time.