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Anyone else searching for this problem twenty years from now, part of the problem is that even though the ereader can "see" a 16gb card, once you go over 4 gigs things get really screwy. Took me a lot of frustrated experimentation and many hours trawling fifteen-year-dead forum threads to figure that out lol.
Apparently Sony decided not to mount the SD card (in the traditional Linux use of the term "mount") but instead use some convoluted custom way of reading it in order to maximize battery life. After repartitioning the SD card so that it's got a 3.9 gig FAT32 ebooks partition and then twelve gigs of Nothing At All, I've just loaded it up to the absolute brim and had it index the whole lot with no SD card weirdness.
Since I've started this thread I've been replacing batteries and cleaning up and handing these ereaders out to my friends and family, and everyone loves the feel of these things. Despite this SD card mystery I'm still very much in love with mine; sure sometimes it takes a few seconds to open a book and I've gotta take a booklight to bed with me, but it's hard to grumble at an aluminium case, three weeks between charges, and Buttons Galore!
I've got a guide in progress for folk who are still in love with these things and want to continue reading books on them eighteen years after they were made, I'll come back and link to it here once it's finished.
Thanks for your good work on Calibre, kovidgoyal!
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