Bad flash card. check disc found numerous problems, running the fix appears to work but once the system use hit the bad sectors the allocation errors returned. Disc doctor did not work and wiping it clean and reloading had exactly the same problems. I replaced it today after testing it here for hours and bombing it with calls. Seems ok now, we will see. You can't get an rma just for the flash card, you have to return the whole thing, so that's what I'm doing. Pity the dealer that doesn't keep stock of their products.
Mark