I think SanDisk has got a serious problem with their quality control. Too many folks are having these problems with a variety of different size SD Cards from that company. Anybody listening out there? Rightly or wrongly, your reputation is taking a severe hit.
My latest test confirmed I can bomb out this card quite easily by forcing intensive write operations. As an example, last night I downloaded and tried to install PocketDos to the SD Card. Failed install and the card was trashed. Filled up with those cluster sized CHK files again.
I deleted the PocketDos stuff that did get installed and then did a re-install to the default location. Installed just fine and the DOS 6.22 emulator fired up just fine.
On reflection, my previous attempts to save system memory by installing apps to the SD Card have led to the same condition.
Until someone really pins this down (maybe a flash upgrade to the Axim itself), I think I'll just stick to putting data files on this device and I'm definitely in the market for a new, non-SanDisk replacement.