USE A CF to IDE ADAPTER...lol....
This enables you to have partitions (more then one) and it really makes your life easier.
Make sure you use fat32 instead of FAT16 or FAT12.
We had problems with several CF cards because of the BIOS LARGE-LBA TRANSLATION (!!!)
Several
cards worked, many didn't, looking at the cards (with the same brand,
labels, fabrication numbers and everything) we noted that there was a
difference in heads, cylinders and sectors. Disabling LBA/LARGE translation
solved our problems (which we found out after lang days and nights
troubleshooting).
Fdisk, format/s from a ms-dos environment. Windows98 for instance (We used Hirens BootCD)
Copy files from a graphical environment (WIN PE or XP, or BartPE or MINI-PE or something alike). If you don't you can have problems with
the long names not being copied.
If you ever have a card that
seems to have bad sectors or does not boot, don't throw it away yet.
Try to fdisk, format/s and copy the files all over again and in our case
they _ALL_ worked again.
Anyway, hope to be of help to someone being as desperate as we were :)
Richard.