[vbat99]

Thanks Milhouse. I've noted the changes for my notes. Will try again a bit later.
Just an FYI, probably the version of XBMC I was using to get a Linux command-line, but I could type
DISK="/dev/sdb"
but when I typed
PART1="$(DISK)1"
gave me DISK could not be found.

Guessing that is because /dev/sdb was not mounted?

Anyway, I just carefully typed /dev/sdb and /dev/sdb1 etc, double-clecking my typing as I went.

Yes, the new sdcard was at sdb, sdb1 & sdb2