This is my first post, but I've been lurking for quite a while and done numerous searches on this topic - pardon if I missed anything, and thanks to all involved for such a strong and helpful community!
I've had no trouble getting Leopard (and now SL) installed on my Mini 9, and I love this little machine. HD space being an issue, I use the hell out of the 16GB SD card that shipped with mine from eBay.
However, once every...let's say 2-3 months, the SD card's filesystem (HFS+) suddenly becomes unreadable and I start getting the, "The disk you inserted cannot be..." messages. Disk Utility is no help in recovery (cannot be repaired), likewise Disk Warrior (error 32), and while I lack other SD-capable machines to try it on, I see no reason to think that they would be able to read/recover any data; as the card works perfectly in my Mini up until these sudden corruptions, I assume that the situation would be similar on other Macs. If I reformat I'm back in business without issue - minus my data, of course.
Has anyone else experienced this issue? I realize that it could technically be a fault in the card itself but that seems unlikely, and even if I were to try a new card it would be months before I could confirm or deny that premise.
Failing that, any suggestions (aside from keeping a good backup)? I'm thinking of trying a different file system, but only because I can't think of anything else to fiddle with. Considering that some people actually run OS X from the SD, that seems especially like a shot in the dark.
16 GB Class 6 SD Card
Disk Utility reports Invalid Nodes, cannot repair.
Disk Warrior begins rebuild but detects multiple (50+) overlapping files and errors out with -32.
Dell Mini 9
OS X 10.6.2