ok i dd'ed the 64gb sandisk to the 128 failing sjcam SD card - threw it in teh 5.5G and rockbox boots!
here's an fdisk dump as it's being read via the ipod through linux.
Disk /dev/sdb: 116.48 GiB, 125069950976 bytes, 61069312 sectors
Disk model: SD to CF Adapter
Units: sectors of 1 * 2048 = 2048 bytes
Sector size (logical/physical): 2048 bytes / 2048 bytes
I/O size (minimum/optimal): 2048 bytes / 2048 bytes
Disklabel type: dos
Disk identifier: 0x63e0d1fd
Device Boot Start End Sectors Size Id Type
/dev/sdb1 * 512 26111 25600 50M 0 Empty
/dev/sdb2 26112 31183871 31157760 59.4G b W95 FAT32
A curious thing I noticed when I first put one of the non working cards on this distro it's dump on an fdisk was:
Disk /dev/sdb: 116.08 GiB, 124644229120 bytes, 60861440 sectors
Disk model: iPod
Units: sectors of 1 * 2048 = 2048 bytes
Sector size (logical/physical): 2048 bytes / 2048 bytes
I/O size (minimum/optimal): 2048 bytes / 2048 bytes
Disklabel type: dos
Disk identifier: 0x8817a9c6
Device Boot Start End Sectors Size Id Type
/dev/sdb1 * 2048 104447 102400 200M 0 Empty
/dev/sdb2 104448 243445759 243341312 464.1G b W95 FAT32
Then after going through a normal procedure where I set it up via fdisk it goes back to being read as its normal size (128gb)
Disk /dev/sdb: 116.08 GiB, 124644229120 bytes, 60861440 sectors
Disk model: iPod
Units: sectors of 1 * 2048 = 2048 bytes
Sector size (logical/physical): 2048 bytes / 2048 bytes
I/O size (minimum/optimal): 2048 bytes / 2048 bytes
Disklabel type: dos
Disk identifier: 0x0f150533
Device Boot Start End Sectors Size Id Type
/dev/sdb1 * 512 26111 25600 50M 0 Empty
/dev/sdb2 26112 60861439 60835328 116G b W95 FAT32
You'll notice that the byte sector has NOT changed in either dump - yet fdisk read it the first time as a 512gb disk. In anycase, this suggests that this is not an issue of SD card compatibility and one of configuration and how the SD card/various layers between it and the user configuring the card. That said I better actually test this boot and ensure that the data integrity remains on this particular SD.
** Update
Looks like I spoke too soon - i can copy files over but something is messing up majorly

the file copy regularly crashes out and is unable to get passed a few tens of mb before windows gives up and tries again. Anyway we're somewhere at least!