All you should have to do to move /opt to the SD is:
1. Kill Opie
2. "cp -a /opt /mnt/card/opt"
3. "rm -rf /opt"
4. "ln -s /mnt/card/opt /opt"
5. Reboot
You didn't say if you are running Opie or not, but I just assumed you are.
Make sure not to make any mistakes with those lines, the 3rd one can destroy your system with ease.
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Ok, when I follow those steps exactly I get this error in the boot log in system info under opie on OZ 3.5.3:
<3>sd : cmd [ 12 ] response [ 3f ]
<3>sd : cmd [ 12 ] response [ 3f ]
<3>sd : cmd [ 12 ] response [ 3f ]
<3>sd : cmd [ 12 ] response [ 3f ]
<3>sd : cmd [ 12 ] response [ 3f ]
<3>sd : cmd [ 12 ] response [ 3f ]
<3>sd : cmd [ 12 ] response [ 3f ]
and it repeats..alot...