Thanks for the incouragement!
I took the original 3.0 DL loaded it up and it got me back into testmode once there I swapped SD to the EW backup files and did the EW copy/paste and again it warned of not enough disk space...so I popped the SD back in the PC and slashed and burned the US POI's the EW Voices,Buildings and POI's...put it back in copy/paste ect....this time it did not warn of free space so I let her rip....it loaded up everything. I followed the instructions...remove SD card,shut off car...with car off install 2nd SD card and restart car.Well it brought up the Update screen in red and was "file searching" for over 30 min. and in the lower bar it said incorrect information on SD/USB! so close!
So right now it will start up to main menu but the system start up bars stays on. The radio/CD works but it restarts after 2-5 mins it allows me access to the settings and shows ver, 3.0 but it won't go to GPS/maps it just gives the Nav warning screen and it shuts down.
Right now I'm re-downloading the update from the EW backup files thread to see if I somehow corrupted the original while loading and unloading these SD cards.
Any other Ideas? was it ok to remove all of the POI's,Buildings,Language and Voices?
Thanks Again Chris, I was very close to placing this unit gently under a bus tire!