If running CWM, you need to verify your version says 18.104.22.168 when you boot it. An older version (like 22.214.171.124) would have trouble formatting data if you were on newer B&N versions.
TWRP would be the latest version (126.96.36.199) and should work, but you'd have to figure out the menu's (not hard) since my guides are for CWM.
Does TWRP let you format data and caches? If it can't open your file, are you sure it isn't corrupt? If you plug the card into your computer, can you open it from the sdcard? It's recommended to check CRC on these files, but I just open them with WinRar and click the "test" button at the top.
Have you tried a new card? You can get a new one for less than $10.
Sorry for all the questions. If it boots, it has to work. Creating a card that boots is the hard part. If it doesn't work, it has to be something else.