So to make sure I wasn't bat-shit crazy, I put the 120GB back in the system.
Went through the same steps of partitioning in WinXP, rebooting Win98 and formatting, copying files over in Win98, rebooting in WinXP, and files weren't readable again.
What I dont understand:
I was previously using this 120GB drive as the primary drive in this computer.
The BIOS detects it with no size problems.
I've installed Win98 to it all alone with no reading issues.
I've installed WinXP to it all alone with no reading issues.
Is this some sort of 1-in-a-million setup voodoo where these two components in this particular software setup just wont play friendly? Lord it makes no sense.
I wish I had another 120GB drive to put a nail in the coffin to determine if it is size that was the issue for my setup (120GB), or just particular branding (Samsung)...?
I'd like to thank everyone for all their suggestions! The 32GB limit on FAT32 seems like it would've been completely valid and a fail-safe solution. So that was all the more frustrating when that wouldn't even get the 120GB to play nicely...
Pictures again uploaded in backwards order. Man this is such a weird glitch in this setup!!
And let's not even talk about how my plans for two video cards in a Dell Dimension (again 98 and XP dual boot) also didn't work out at all. I guess this just aint my week...
Shout out to LGR and PhilsComputerLab!!