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So using Check Flash 1.10 i have done the following:

1) Full Format

2) Write and read test, using 1 cycle, and access type = As physical device (NT-based systems only) - No errors detected

3) Then i copied back my data (installation files, ovi map data) using teracopy and put CRC testing on, all files copied okay, no errors

4) Then i again did a Read stability test (1 cycle) and no errors:

Pass #1 completed, 0 errors found.

Test completed, total 0 errors found.

Next step, hard reset of my phone, then pull out the memory card and do another test (in case the hard reset somehow affects the mini sd card).

So i opened Ovi Maps 3.0 first, now i've taken the Memory Card out and put it back in my PC, doing a Read stability test using the same options as before

Pass #1 completed, 0 errors found.

Test completed, total 0 errors found.

But then when running a CHKDSK:

I:\>chkdsk
The type of the file system is FAT32.
Volume REMY created 2010-01-08 11:47 AM
Volume Serial Number is 1088-4A57
Windows is verifying files and folders...
Windows found errors on the disk, but will not fix them
because disk checking was run without the /F (fix) parameter.
Unrecoverable error in folder \Music\Mp3\
Convert folder to file (Y/N)?

Is it OVI Maps thats causing the issue??

I'm going to format again, copy over, then do a CHKDSK first

So formatted, copied again (no CRC errors) then did a CHKDSK:

I:\>chkdsk
The type of the file system is FAT32.
Volume REMY created 2010-01-08 03:48 PM
Volume Serial Number is CE42-A8E3
Windows is verifying files and folders...
File and folder verification is complete.
Windows has checked the file system and found no problems.
7,732,464 KB total disk space.
184 KB in 44 hidden files.
1,876 KB in 447 folders.
4,995,268 KB in 2,322 files.
2,735,132 KB are available.

4,096 bytes in each allocation unit.
1,933,116 total allocation units on disk.
683,783 allocation units available on disk.

So no problems!

Lets start this again, putting the memory card in and doing a hard reset, will see what happens (Won't open OVI Maps this time)

So i pulled it out and did a CHKDSK, no errors:

I:\>chkdsk
The type of the file system is FAT32.
Volume REMY created 2010-01-08 03:48 PM
Volume Serial Number is CE42-A8E3
Windows is verifying files and folders...
File and folder verification is complete.
Windows has checked the file system and found no problems.
7,732,464 KB total disk space.
184 KB in 44 hidden files.
1,888 KB in 450 folders.
4,995,312 KB in 2,324 files.
2,735,076 KB are available.

4,096 bytes in each allocation unit.
1,933,116 total allocation units on disk.
683,769 allocation units available on disk.

So now i've put the card back in, opened OVI Maps, put on Voice Guidance and downloaded my license.

Took the card out again, did a CHKDSK, not much has changed (at least no errors)

I:\>chkdsk
The type of the file system is FAT32.
Volume REMY created 2010-01-08 03:48 PM
Volume Serial Number is CE42-A8E3
Windows is verifying files and folders...
File and folder verification is complete.
Windows has checked the file system and found no problems.
7,732,464 KB total disk space.
184 KB in 44 hidden files.
1,892 KB in 451 folders.
4,995,316 KB in 2,325 files.
2,735,068 KB are available.

4,096 bytes in each allocation unit.
1,933,116 total allocation units on disk.
683,767 allocation units available on disk.

This really looks like an intermittent issue with the Nokia 5800XM, i will take each new installation step by step to see what could be causing the issue.

So next i installed Mail For Exchange (which installs by default on C) and so far no problems.

Then, i installed TweetS60 on the memory card, still no issues experienced.

Finally i instaled Gmail 2.06 with fixed installer on the memory card, again no problems.

Will see if i can run this stable for another 3 days