I use a Transcend 8GB and get it on the first file of the night. After that no problem. I have gotten use to it happening so, it doesn't bother me any more. I always format after I am all set up so, the first time it happened it was not big deal. It has never happened with my 4gb Kingston.
One thought I had was that maybe the cards that have the problem have just slightly more capacity than the ones that aren't having the problem and they are beyond some memory barrier or something (speaking of which, has anyone gotten and tried a 16GB card yet?).
The capacity of my Sandisk is: 12 hours, 51 minutes 23 seconds or 8,200,970,240 bytes
I also have a Seagate 8GB MicroDrive. It's capacity is: 12 hours, 30 minutes 32 seconds or 7,979,319,296 bytes
(the time is the record time at 44.1/16 bits as reported by the MicroTrack, the bytes is the capacity number (not just free space) of bytes reported by Windows XP after formatting the card in the MicroTrack and then immediately booting into card reader mode with it.
J.T.