Not sure what's going on now. The zip file created a subdirectory on the card, despite pointing the unzip location to the root directory.
The zip file has files that go in the root or top directory. These are essentially the core CHDK program itself and a couple of text files.
It also has a subfolder called CHDK where all the rest of the files needed for CHDK are stored.
So what you saw was perfectly normal.
I started over, formatting the card and reinstalling the original 101b build, but now the camera won't recognize that CHDK is present - it reads it as an ordinary locked card. Same result if I unzip the new build into the card.
When you reformatted the card, you wiped out the special configuration that STICK did to the card's master boot sector.
To boot with the "SD Card Lock" method, two things are required
- a file called DISKBOOT.BIN in the root folder
- a special signature ("BOOTDISK") stored in the SD cards boot sector starting at offset 0x40 (decimal 64) on a FAT16 volume and at offset 0x1E0 on a FAT32 volume.
You need to rerun STICK to get the "BOOTDISK" signature rewritten.