Default Formatted sd card messing up backup ability

After a lot of forum research I was finally able to successfully root, install cwm, and miui onto my wife's fascinate. I used cwm and made a backup on her stock rom, a backup of her miui, and used titanium to backup her apps. Everything was fine until last week she had an issue while trying to update miui causing the sd card to show as blank or having a bad file extension.and Ultimately we ended up having to format the card. Now with a formatted sd card I cannot backup any images of roms. Using red cwm I get an error saying e:error/dev/block/stl11 and e:recovery/log/file already exists. I am assuming this is because the new card does not have any of the files on it, but when i tried putting them in the root it still does not work. The phone and current miui rom work fine, and I can Odin stock froyo if necessary, but I would like to get things back to how they should be. Aside from using odin to flash back to stock and starting all over is there any way to get the necessary files onto the sd card to make things work correctly. I've seen other similar thread but in most the phone seems to be not working at all, ours works but just wont let you backup or flash roms now.