fat 32 drives can report a wrong size if there is a small error on the drive, which scandisk fixes, is it the same for ntfs, in which case a chkdsk could be the answer. also investigate the reserved space for the recycle bins (one per account) system restore, and possibly internet explorer cache. (i remember an ie 4 cache bug which could fill up your hard drive, back in the olden days

) i don't know if the space for these things is taken off your available space in advance. hmm slave drive, then probably not ie cache, then.