Those with interest in the initial topic please read.
My latest discovery on this troublesome issue. The
card appeared to be filling up with blank folders. It turns out it happened again and they were actually 2K "chk" files. Remember the old chkdsk /f dos command that would scan your drive and create these file fragments. You could then at least delete them to free up space. Why they were all 2 KB is anybody's guess.
My SD
Card format was FAT 16, 512 byte sectors and 2 KB clusters. I have no idea why this storage media was going nuts and filling itself with .chk files, but clearly this is not acceptable behavior. The SanDisk site had nothing to say on the subject.
I downloaded and installed a utility called StorageTool ($14.95).
http://www.softwinter.com/storagetool.html
I was troubled from the git-go that this
card never requested a full blown format prior to use. I used StorageTool to reformat the device. The program gives you the option for fat12, fat16 and fat32. I stuck with fat16, but changed the cluster size to 4 KB. The process took a couple of minutes, which was a good sign. Before when I was prompted to do a format, it was almost instantaneous so I didn't really believe anything good had happened.
After formatting I ran the disk verification checks and defrag. Everything looked good and the tool was reporting 120 MB available which is about right for a 128 MB disk.
Rebooted and surfed the web to populate the Temporary Internet folders. I then cut and pasted a bunch of files onto the disk. Did a soft reset and ran the tools again. Everything was reported OK, so we'll see what happens next.