With the card I had, I wasn't given the option for 32K block size unless I went through command prompt. Windows only offered "Default" (4K). Using Vista SP2 I am able to select 64K block size instead of 32K. XP told me the card wasn't compatible with 64K block size. Testing 64K block size now with the various zImages listed in this thread. So far, backed up my dingux partition and tried tossing the zImage on and it failed to load. I noticed this problem every time I went to change the zImage/rootfs I needed to format the SD card. I am wondering if maybe dingux writes something to the start of the card when it is first run or something? or do the rootfs and zImage have to be the first files on the disk? If the latter is the case, that would explain why I always had issues updating to the new zImage (and probably solve the issues that others are having), but it doesn't explain why when I put the "working" zImage back on (without formatting) the dingux boots properly.
May need to grab a copy of the dingux source and read through the whole thing (large project that i don't currently have time for, but be good for in the future).
crossing my fingers...
Thanks for the new zImage and thanks for all the info that everyone posts... it keeps me motivated to keep poking at some projects (and testing).