Thanks for the advice
I tried a few times - syncing through calibre one book at a time, and letting my nook rest with a 1 hour timeout - still no luck - only about 20 books are adding, and all error strewn files (Empty Book Cover with no title and author just a file name) - these same books work fine when sent to the device. Also tried it with 2 different SD cards.
I tried this a few times over the last 24 hours, but no luck
Does @Kovid have any ideas? I'm at a complete loss...
Thanks a lot guys!