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I can't guarantee what I'll say here is true...just my observations re: SD card problems.
I think the issue with some cards is that when you "delete" a file the card isn't releasing the space back properly. When you delete a file it doesn't clear the data, it just drops the files association within the cards file stucture.
When I've deleted a file I've run an "Analyze" from the Defrag screen of StorageTools. It finds that file space as "fragmented" and requires a defrag.
The free version of StorageTools doesn't let you defrag unless you register it, so I haven't yet run the defrag to see for sure if it cleans it up properly, but I assume it does so.
The only time I've had a problem with my SD cards is if their nearly full, then some files are deleted, then I try to write to it.
Chris...
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