Good advise guys. I have had excellent results just using my OS to format the SD card. Also Wal-mart sells a 1G SD card for $5.99. Those who are computer savvy can re-use an existing SD card and can make it work flawlessly but for the first timer or for the guy who is not a computer guru it makes sense to just use a new SD card

The .sax file on a brick unit not working on other units is a great point. The original file WILL BE unit specific! I did not clarify that at all. Good catch. There is a work around for this but requires a lot of computer chip experience with flashing software. So what can the average joe do if he has crashed his TX and did no make a backup of the original firmware? Unfortunately, the files are not open source which means you can not get spectrum to show you the architecture and software file.

Here are two suggestions:
1. Buy a junk radio of like kind (maybe one with broken gimbals or case or the switches are broken off) and use the motherboard off that unit and rebuild with necessary components from your good unit. The junk TX will have to be a working processor in order to retrieve the info needed. If not, your going to be right back where you started
2. Do a hard reset ( each unit is different) but usually starts with pressing and holding certain buttons while turning on and then flipping a ombination of toggle switches several times. I have been successfull doing this on a DX7 and a JR 9503 both of which were brick units when I received them. It would be nice if some spectrum guru with firmware could make a file showing the combination of sequences to get to the root menu for each unit.