Try this guide for USB pen flashing.
http://csd.dficlub.org/forum/showthread.php?t=1136
You'll have to use your working card to change the boot sequence and stuff, though, obviously. Before installing the old one.
And .rom and .bin issue is not a big one, really. Just rename if necessary. Perhaps you used the old version of the flashing program or something... Because when I flashed my card .bin worked fine. Using AtiFlash 3.75 I hope?




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