Thanks!
I'm going to have a look at it when I get home

From what I had seen at always innov's website was to extract, I didn't think it would be so..... awkward

I will try extract to SD.

sudo -s
tar -Oxjpf ai-superjumbo-2011-03.a.tbz2 | cat > /dev/sdb

Edit: I used the above command on an unformatted SD.
I took ages, extracted and formatted the SD card on it's own.

It added a bunch of files to the first partition (kernel and such). But the second partition (main OS) has 'Lost and Found' and another file that says it's empty, but 2.4gb is used. When I dig out my power cable I will boot up my beagle.