My system cannot see the card if it is not mounted
Is this because the card-reader shuts down when you umount the card?
Try formatting it on the Zaurus.
Si
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It should work if you do this with the card inserted:
# su
# umount /mnt/card
# mkfs.ext2 /dev/mmcda1
Then you can remove and reinsert the card and it should be formatted as ext2.