I tried formatting the card using MiniTools, SDFormatter, CWM recovery and within Android but still card mount it.
Anyone with ideas on how i can reformat the whole card back to its full capacity in FAT32 so i can start from scratch?
PS. I don't have access to a desktop machine with an internal card reader.
My SD Card won't mount from within the Android OS (Custom ROM - TheUltimatum 2.3.7 for Galaxy Ace) yet i can mount it in CWM recovery 5 - even then it doesn't mount the full capacity. This is after i partitioned the card using MiniTool Partition Wizard - One FAT32 and One Ext2. This was in preparation to use Mound2SD to move some of my Apps, Data and Dalvik Cache to the SD Card.