You can send a 4 gig CF to Short Tronics and he'll install Palm OS on it for you. Did it on a SanDisk Ultra II for me for $25 plus $2 return postage. (Of course would be more outside the USA.)
Have you tried a Secure Erase? The card I got back from Short Tronics had a corrupted Music folder that looked like a file. A Quick Erase didn't fix it but Secure Erase did.
You'll want to have the power cord hooked up because it still takes quite a while.
After I did the Quick Erase, it'd go to a blank screen with the default DIA showing after tapping Done. So I reset it, same thing. The Hotsynch button on the cable did nothing.
Reset it again then instead of Done I poked the Web icon. That worked, so I poked the Mail icon. That opened a box saying it needed to Hotsynch... Ah ha! I poked that and it synched and everything transferred back, but the corrupted Music folder was still there.
Did the Secure Erase then just went to Mail to synch. Corrupt folder replaced OK and all my stuff back except for what was on the "drive". (Just a couple of videos I have elsewhere.)