a couple more suggestions, you mentioned you formatted the card, have you partitioned it at all? could be the wrong partition is screwing something up. also how much room is on your card? you'll need a minimum of 500mb after the android files are on the card.
Quote:
The system fails to boot, saying something about "Cannot mount SD Card"
This is usually due to the card being incorrectly partitioned. Some have reported luck using the HP Disk Tool (Google) to repartition and reformat. If you have access to a linux distribution, GParted can easily repartition. The correct state is one primary partition (the failing cards tend to have one extended partition, containing one logical partition).
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this may be of help too. i know the error is different but it's worth a try.
have you had android running previously with other builds?