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I second your thought that the test might be more valid using the same file. Let us know if it turns out to be the card. As for the class four cards being faster the argument is usually made based on the card's abilities to process smaller files more quickly due the card's design and block size. Specifically it would likely be most important to consider when replacing the internal card which handles smaller files as part of the firmware which it holds. Larger files might be faster on a class 10 card being used externally for file storage only.
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