I had the same issue myself, but after seeing that post about 0000EA00h*200h working, I did that and it worked. What procedure are you using exactly to do this? Is it on a PC?
mkcf input.cf output.cf 30670848
ntrw write output.cf 30670848
If that doesn't work, then maybe this will work:
mkcf input.cf bigbad.cf 64225280 <= The true size of the SanDisk 64MB card, 1EA00h*200h
ntrw write output.cf 64225280 <=This should overwrite everything on the card
mkcf input.cf output.cf 30670848
ntrw write output.cf 30670848
This will at least fill the 2nd half of the CF card with 00h. Perhaps the Audrey doesn't even look at this area of the card, but I just thought that the possibility might exist.
I got my Audrey last week and the 64MB CF SANDISK probably two days ago. I have been hesitant to use the EA00hx200h because (1) It simply isn't the size of the card and (2) the Audrey is, as you mentioned, reporting a sector size of 240h instead of 200h. I was concerned that the Audrey might not live through the upgrade because she was misreporting that sector size. Wuzzup with her anyhow? 240h=576....kind of like 64bit*9bit instead of 64bit*8bit.
Thanks,
MKanar