I did more investigating about this issue and discovered some interesting facts:
Windows Operating Systems format the clusters (byte grouping of data) in different ways depending on the detected volume size. Do not allow Windows 98/ME/2K/XP to format using FAT 32 or NTFS. I know Windows XP using FAT 16 (or FAT 12) will select a cluster size from 2KB to 64KB.
I wonder what cluster size the embedded software of the Neuros MPEG 4 formats at?
I use my CF cards for my recorder and my digital cam. I found this nifty site that fixes the problem with the CF card problem as you described.
http://www.datarescue.com/photorescue/ [8D]
Ex-Navy