Never had a problem w/my 256 SD, which I never take out of my axim. I have some big files too. like the bmw films (3) etc...
In fact I was down to 50 mb on My 256. This was a big discussion on the PC passion site as well.
I brought up the fact that I never take my card out and wondered if handling the card a lot could have some adverse effect?
I also found a defrag program from
www.softwinter.com
that I checked my card with. I was 65% fragmented and after I ran the defrag program (several hours on the 256!) the SD card seemed to load files and programs quicker... seems to make sense!
Rik