Have you tried using the USB Duplicator Image Creator and USB Duplicator Writer
http://www.vconsole.com/client/?page=page&id=28
http://www.vconsole.com/client/?page=page&id=29
Even if you are only trying to make one Duplicate, instead of many,
these tools are designed to make exact copies.
Luck;
Ken
PS; If you are duplicating the contents of a smaller drive/card onto a larger one
you will need to extend the partition, to get full use of the larger card. That is
easily done with a partition manager like the "MiniTool Partition Wizard" the
home edition is free.
http://www.partitionwizard.com/free-...n-manager.html