But no matter how I try to format the partition it comes out as 2.9 GB.
Who says that (which program) ? There is not a single program for OS3.1 which can deal with sizes bigger than 4GB correctly. But this is only a cosmetic problem. All functions work correctly nevertheless.
HDinstTool reports the disk as an 8 GB when it is in reality a 40 GB.
Don't use HDInstTool, use HDToolbox. And make sure that the geometry data is determined correctly. If the tool does not read it correctly, you have to correct the values manually.
Note: 16 heads, 63 sectors and 16384 cylinders is *not* the correct geometry. This is the maximum for old PC BIOSes and limits the size to 7.8 GB.
Search the manufacturer's documentation for the total number of user sectors for the drive, divide it by 1008 (= 16 * 63) and use the result as number of cylinders. For 40 GB you should have around 77500 cylinders.
Note that HDInstTool does not let you override the geometry. That's the reason why you should use HDToolbox.
And note well: once you've choosen one program to edit partitions and created some partitions with it, you must not use any other program to do the same. Especially when switching from HDToolbox to HDInstTool, all your partitions will be lost.
Bye,
Thomas