Definitely try the h2test utility Tapeworm recommends, to see if the card is OK. There are plenty of bogus cards out there, what they do is write a fake directory on the card (the SD Formatter rewrites part of this area).
As for cluster allocation, the Sansa does great with 32kb clusters , as opposed to Windows’ tendency to favor 4kb. The smaller size causes some serious overhead in reading from the card.
Bob :smileyvery-happy:
