Let me back up a couple notches here :-)
I had originally put together the prep-home-sd script (and modified rc.sysinit script) without any swap file, then sent it into Proto to include in the tkcrom. Then we started going over ideas to improve it a bit. Proto thought it would be a good idea to then turn the ramdisk into a swap partition, since it was no longer being used for /home, so he added the mkswap & swapon to the end of the script and included that version in the tkcrom 2.0 alpha-3 release. However, since a fsck is run by rc.sysinit before the rc.card script is called, this would cause the fsck errors that you see.
Meanwhile, I had fallen off the face of the plannet (read: got bogged down with work). Later, I sat down a my orignial script (without the mkswap) and overhauled it (added a swap file (not a swap partition), moved some stuff around, etc). I\'ve been waiting to here back from Proto, but I take it that it\'s his turn to get over-loaded with non-Zaurus activities :-).
The version of the rc.card script you posted above, is not generated by the new script but is the one generated by the (old) prep-home-sd.sh script included in the tkcrom. So, one of two possibilities: 1) you probably ran the old version of the script (the one on the tkcrom) by mistake, or 2) you ran the old version originally, and for some reason the new version didn\'t overwrite the rc.card that was put on the sd previously. To make sure that you are running the right version, specify the whole path of where you put it. Also, the new version has better help (the help text should pop up if you don\'t specify any parameters). Or, a third posibility is that I upload the wrong script. Nah, that couldn\'t happen :-)
Good luck,
--derek