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Update: USB seems to be the problem
I have tested the flash memory extensively and found that there are no bad blocks anywhere on it that can be detected. Also, I used it altering the file system a great deal for a couple of days with heavy use through telnet and ftp only with no problems.
Not sure who or what to blame for the apparent USB problem. The linux version on my desktop os (Fedora 15) definitely has problems with USB from time to time, not being able to safely power it down. The Kde Dolphin file manager also has a bug whereby it says "safe to remove" when in fact it has received an unreported error message that the removal had failed. In this case it has unmounted, but it has not powered down and ejected. In theory I think one should be able to remove without an eject, but empirically, apparently not. (I mean, the OS should have completed all its buffering and stopped all other legitimate access to the drive before it unmounts. Obviously if one is writing the drive other than through the file system, one could cause problems after an unmount, but otherwise, I would have thought not).
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