I managed to get my original broken USB drive to work.

1.) Manually mount drive
2.) Copy files to local disk
3.) Format USB drive
4.) Use mkdosfs to create new FAT32 filesystem
5.) Copy files to USB drive

Now it works under Mac OSX (and OS9, actually), Linux and Windows and
automounts under all of them.

[EMAIL PROTECTED]:~$ echo "drive i: file=\"/dev/sdb1\"" > ~/.mtoolsrc
[EMAIL PROTECTED]:~$ sudo minfo i: | grep disk\ type
disk type="FAT32   "

That's the magic.  If that's blank (as it was orignally), then it
doesn't automount.  I'm still unsure as to why that particular attribute
was set to blank, or by which OS.  What I also found when the attribute
was blank was that the drive failed to auto mount on Mac OSX.  Only on
Windows did it work.

-- 
USB Thumb Drive can't mount anymore in Hardy
https://bugs.launchpad.net/bugs/211760
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