getting an r4i sdhc to work- keep getting Savfile not Found, please reset system

I downloaded the most current firmware version but kept getting this message (see above) so I tried an older firmware version that is working.Other than the games I copied all the files exactly from the flash card that works but continue to get this message when I try and play a game. I even copied the games Savfile from the other card and used the same r4i card (shell).Does anyone know what I am doing wrong? (other than not using an ACEKARD)
Post Merge: [time]1266506615[/time]
nobody else is getting this error message?I even tried copying my working flash card and inserting it into the same R4i-sdhc red and I still get this message. I also have a r4 gold, but their site is down and I can't get the firmware.