... for an apple & an egg ...
/dev/disk5: 7744000 sectors in 60500 FAT16 clusters (65536 bytes/cluster)
That looks good. All need is the full installation unzipped on Your card.
(There are other computers in the world) Then You can make the card bootable in the CHDK-menu.
MENU_ITEM (0x33,LANG_MENU_DEBUG_MAKE_BOOTABLE, MENUITEM_PROC, gui_menuproc_mkbootdisk, 0 ),