OK, that was an interesting portion of the thread, sorry we couldn't help out more Tony.
My main reason for updating these tools was to see if we could effect a positive outcome for people with 'dead cards'.
Unofrtunately it seems that the problem is a little more fundamental and could be either driver related or something related to spec of card/card reader in Z (write voltage for card ?, clocking discrepency ?).
Anyway the tools do seem better at a couple of things, sizing large cards - getting the geometry right and maintaining ext3 file systems.
I think Tony's case illustrates, however, that you still need to be careful with your choice of card and your decision as to format it/repartition it or not.
- Andy