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the happycheesecake tests may not be appropriate for these cards. it was designed specifically for Sandisk SD cards having corruption issues in the X5, but your cards appear to be OK in your axims.
i am not sure how to explain your problem, but I have a normal Sandisk SD card (which passed all the happycheesecake tests with flying colors) that worked fine in my Axim X5 (when i had it...), my Simpletech card reader (link below), but not in my built-in desktop card reader.
the problem in the desktop card reader was different from yours, but it might indicate an incompatibility with the reader. If you have easy means of getting another reader you may want to consider that. If possible, test the cards in other readers to make sure the problems are really the cards' faults.
It might be more of an issue with the cards, though. What did you reformat to? Try FAT16, FAT32, and FAT. Do you get the same errors no matter what file you copy or just that one (or just around a certain file size?)?
Sandisk is pretty good about replacements. If you are unable to find a fix, you can also try the replacement route.
good luck
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2x SimpleTech Bonzai USB2 mini-drive/SD card reader
2x Lexar 1GB (Non-Hi Speed!) SD (USA): write speed = 5.5MB/sec (37.5X) Space avail. (formatted) = 975MB
1x SimpleTech 512MB SD (Taiwan?): write speed = 5.3MB/sec (36.4X)...... Space avail. (formatted) = 489MB
RMA'd: SimpleTech 512MB SD (Japan): write speed = 3.9MB/sec (26.6X)... Space avail. (formatted) = 491MB
Sold: Viking 256MB SD (Taiwan): write speed = 1.5MB/sec (10.2X)........... Space avail. (formatted) = 241MB
Sold: Viking 128MB SD (Japan): write speed = 1.5MB/sec (10.2X)............. Space avail. (formatted) = 120MB
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