Debian size and uSD

[Jeffrey Ratcliffe]

I bought myself a 4Gb uSD card and decided to have a go at moving the
(full) 512Mb partition onto it, using

http://inferno.slug.org/cgi-bin/wiki?Drive_Backup_And_Cloning

as my reference. I backed up the 512Mb with no problem. The 4Gb card
was not recognised, though; dmesg on the desktop produced:

[ 2460.876027] usb 5-8: reset high speed USB device using ehci_hcd and
address 10
[ 2461.010393] sd 5:0:0:0: Device offlined - not ready after error recovery
[ 2461.010444] sd 5:0:0:0: rejecting I/O to offline device
[ 2461.010462] sd 5:0:0:0: rejecting I/O to offline device
[ 2461.010471] sd 5:0:0:0: rejecting I/O to offline device
[ 2461.010477] sd 5:0:0:0: [sdb] READ CAPACITY failed
[ 2461.010482] sd 5:0:0:0: [sdb] Result: hostbyte=DID_NO_CONNECT
driverbyte=DRIVER_OK,SUGGEST_OK
[ 2461.010489] sd 5:0:0:0: [sdb] Sense not available.
[ 2461.010496] sd 5:0:0:0: rejecting I/O to offline device
[ 2461.010502] sd 5:0:0:0: [sdb] Write Protect is off
[ 2461.010505] sd 5:0:0:0: [sdb] Mode Sense: 00 00 00 00
[ 2461.010508] sd 5:0:0:0: [sdb] Assuming drive cache: write through
[ 2461.010643] sd 5:0:0:0: [sdb] Attached SCSI removable disk
[ 2461.010808] sd 5:0:0:0: Attached scsi generic sg3 type 0
[ 2461.019731] sd 5:0:0:1: [sdc] Attached SCSI removable disk
[ 2461.020480] sd 5:0:0:1: Attached scsi generic sg4 type 0
[ 2461.035667] sd 5:0:0:2: [sdd] Attached SCSI removable disk
[ 2461.036236] sd 5:0:0:2: Attached scsi generic sg5 type 0
[ 2461.045093] sd 5:0:0:3: [sde] Attached SCSI removable disk
[ 2461.045602] sd 5:0:0:3: Attached scsi generic sg6 type 0

OK, I thought, I'll install Debian from scratch, but this failed with:

ext2fs_mkdir: Attempt to read block from filesystem resulted in short
read while creating root dir

Subsequent attempts fail with:

dd: writing '/dev/mmcblk0': Input/output error
1+0 records in
0+0 records out

What can I try before I give up and send the card back?

Regards

Jeff