I'm with tshering, I can't think of what help putting the new firmware on the card would help. It has to boot to the point where this can be installed. Doing a factory reset does the same thing as the firmware upgrade but copies the firmware from the recoveryfs partition. If that doesn't work, then the upgrade probably won't. I also think it is important to get factory reset working as that is a quick recovery from a non-working device.
I also have to think about how to add the files. I suspect the simplest is to put the image on card, add the files and do another image. No matter what, I won't have a chance to do it for a couple of days.
And yes, check the SD card adapter. I have one that is almost impossible to insert in my laptop without moving the switch.
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