Dj, I did do the ext3 format part. I just manually deleted it from fstab. I just reflashed and I'm about to redo it.

-edit-

One of 3 things could be the problem....

1. The 770 isn't formatting that card right
reason: the original 64MB card worked with the same steps I've been trying.

2. The card simply can not hold certain partitions/formats.

3. The card is bad.

EDIT!

It works, I used partition manager for windows. Works fine, wouldn't work though while trying to do it from within the 770.