I copied a couple of big files, a 419MB ATI SDK and a 398MB Beyond the Red Line BattleStar Galactica free game demo, onto the Sandisk Ultra II SD card. One thing that I accidentally learned by doing this is that Windows XP ignores the SD card's write protect tab. That pushed the SD card contents over 1GB in size. On the Zaurus SL-C760, I copied the files from the SD card to the CF card and am currently starting to compute their MD5SUMs. That will take a while. I would be more concerned about SD cards which are larger than 2GB in size in case the Sharp code uses signed 32 bit integer representations which would cause integer representations that are larger than 2,147,483,647 (2^31 - 1) to be interpreted as negative numbers.
I know that the Sharp voice recorder will falsely think that a mostly empty 4GB CF card is out of disk space, probably due to the use of signed 32 bit integer representations for checking the available space.
What technique did you use to disassemble and reassemble the object file? I might have to do that with the Sharp voice recorder to disable its disk space check.
The MD5SUMs of the corresponding files are identical. The computation finished as I was finishing this message.