How should the developers solve the problem if they can't reproduce it?
Only if we users write down our problems, they can find the origin of this bug.
Perhaps it is really a hardware issue.

I've noted this as well, and I'm holding off buying any SDHC cards for when/if this issue gets addresssed. I've also noticed it seems a large number of the complaints involve SanDisk cards. Don't know if that has to do with the wide availability of the cards or the brand itself, but it's still made me leary of that particular manufacturer. I've been running a cheapo 2GB PNY SD in the internal slot for data and the Nokia supplied Mini SD in the external for backups since I got my device about 10 days ago and haven't had any problems (knock on wood). I didn't put either into the device until after I flashed the software update, haven't used either with an external card reader, and have been careful to format them only with the device itself (a few other things I've noted here that may help prevent the problem). Hopefully all continues to go well. We'll see.

the 2gb mini sd (nokia labeled) which came with the nokia/navicore gps kit bit the dust late last week. it was in the external slot, went from working flawlessly (while the navigation software was running) to being 'corrupted' to not being recognized in either slot. tried rehab in the n800 and in both an xp pro and xp home computer. could not resuscitate it, now considering my options. may have to lay it to rest if there are no miracles available in the new future. wonder if nokia or navicore will replace it.
also, just now remembering it did have a problem a few weeks back where it was recognized only as a 1gb card and the navicore software would not run. i kept looking at the contents of the card with the file manager, then moved it to an xp home machine where at first the windows explorer also saw only 1gb and only the few very small files also on the card. then it seemingly fixed itself and had worked up until a couple days ago when it went kaput.

I'd definitely include that tidbit of information in a contribution to the bug report on this
matter seeing as how I recall reading in another thread about another forum member who was recently dressed down somewhat by a Nokia customer service rep for not using a Nokia branded card in his device when he called to complain about his N800 bricking one of his cards.