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Sounds promising. I have a spare 8GB card that I had in my HTC TP2. I formatted it and am using it now. Been 4 days and not a single problem. I think the problem is a bad batch of SD cards from SanDisk shipping in the EVOs. Sprint and RS and BB better be ready to replace them when the EVO goes on sale.
I switched cards with my Hero's 8GB and it seems fine EXCEPT that maybe once a day or so, the card starts running slow (checked by SD Card Speed Test app). A reboot fixes the speed. Makes me wonder if I don't reboot if it will eventually start failing again.
Interestingly enough, I have had issues with uploading images to Picasa where the images show up on Picasa with some corruption (jaggy grey bar at the bottom). Seems to only happen when the card is in the funky slow state. A reboot and reupload fixes it.
Now HERE'S where it gets even MORE interesting...the same thing is happening on my Hero! And I've updated my Hero to 2.1 and it has Sense on it as well.
I'm not saying these issues are necessarily related, but it's simply more data to figure out what may be wrong. Personally, I think it's a 2.1 software bug, probably with Sense.
Would be interested to see if anyone else sees what I am seeing...a slowdown of the SD card throughout the day. Basically, run SD Card Speed Test throughout the day and note down the numbers. For me, by the end of the day, it has a write speed of 1mb/s, and that's when I get Picasa upload issues.
I'm not saying these issues are necessarily related, but it's simply more data to figure out what may be wrong. Personally, I think it's a 2.1 software bug, probably with Sense.

i just found this and though i would share it hope they get it fixed.Updated: Is HTC EVO 4G About To Be Launched With A Massive Defect In The Included 8GB MicroSD Card? Update: Data Corruption Is Now Part Of The Issue | Android News, Reviews, Applications, Games, Phones, Devices, Tips, Hacks, Videos, Podcasts - Androi
what exactly is happening with the sd card, are you getting an error message on the Evo along the lines of "insufficient file permissions"? I'm just wondering because this is exactly what happened to me with my HTC Hero and it occurred not too long after disabling Sense.
aw damn. this reminds me of the stock messaging app issue with the hero that happened when it first got released. i will read through it tomorrow, i don't think i have the energy for pre-troubleshooting ATM