It sounds like the card is flaky. Now that you've formatted the card try doing a backup again. If it doesn't work, try it on a different card.
If it works on a different card I'd exchange the one you have for a new one.
I also have the same card and I am getting the same problem with the backup. When you start the backup, it does check the SD card and replies with the amount of free space. I figured if it can see the card and give the free space then the backup would work.
I will try a new card to see if that corrects the issue.
Any other thoughts on this problem???
Ok, I tried a new SD card from Verizon. I formatted the card using the phone and then ran the Nandroid Backup.
This did not work either. Still getting
no /sdcard/.android_secure found.
Skipping backup of applications on external storage.
Backing up cache.....
No sd-ext found. Skipping backup of sd-ext.
Generating md5 sum....
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