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Well took me most of the day to rebuild my ipaq installation on my card and get rid of stuff i wasn't going to use. Decided to do a low level format followed by a FAT32 logical format of my card. I then installed applications a bunch at a time to the SD and did an ipaq backup followed by a full backup of my SD to my PC. Managed to complete the installation and get to today without any problems.
I am guessing that some kind of FAT corruption was going on but don't know how and somehow the low level format followed by the FAT32 thorough logical format did the job.
I won't make the mistake of not backing up my SD again and I suggest that we have sticky for new owners and put this as a number one priority.
* Backup your SD, CF etc to PC after doing an ipaq backup, it will save you buckets of time cause flash card corruption is a reality!
* Have a spare SD, CF which mirrors your plugged in card so when you are on holiday with no access to your syncing pc you can at least get a 99.99% recovery.
Cheers for everyones help
Fergus
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