Change drive "block size" to 4096
Format the drive using Disk Utility. Find out what disk identifier the drive has (/dev/disk0, /dev/disk1, /dev/disk2, etc…). You can do so in Disk Utility.

Then use the command line tool newfs_hfs to create a new HFS file system on the disk. The command below is taken from here.

newfs_hfs -v HFS_VOLUME_NAME -b 4k /dev/rdisk2s1


This creates a HFS volume with name "HFS_VOLUME_NAME" and a block size of 4k on the device with identifier disk2s1.