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That 2gb card was dead as a door nail. I had a 32gb Samsung evo+ sd card lying around so I formatted that, copied the files over (Jeremy sent me a zip file via email), and it is back again!
A few thoughts:
– maybe include a backup 2gb card with each order just in case
– switch to Samsung 4gb cards, as more space (for dead cell mapping) and name brand helps SSDs be a bit more reliable
– email customers with a backup zip file at the time of order
The evo+ is definitely a bit of overkill, but per my blog entry benchmarks these are the best performing SSDs cards out there at the moment: