I am following these steps every time:
1. Open SDMINSTE.exe
2. Create 2 Partitions 2mb SDM_LEFT, 7600mb SDM_IMAGES
3. Format Partition 1 (2mb)
4. Click Make Bootable - Feedback (Bootable Card !!!)
5. Swap Partitions
6. Format Large Partition (7600mb)
7. Close SDMINSTE.exe
8. Copy CHDK files to the Large Partition
9. Open SDMINSTE.exe
10. Swap Partions, Small Partition is Selected
11. Copy DISKBOOT.BIN to Small Partition
12. Lock Card, Place in Camera