I ended up ditching the "Darwin Ports" method 1 and had success with the "OxED" method 2 as on this page:
Bootable SD card - CHDK WikiI just wish I didn't spend so much time on trying to get Darwin Ports to work. Method 2 took about 5 minutes total.
I'll look over your instructions and try to see where I went wrong. I still need to get my other 3 4Gb cards setup which I understand is going to be a little more of a challenge.
