Need help with Fusing Error

I have been trying to fuse the SD card for a week now without luck.
Regardless of what I do I get errors. I have followed instructions to the
letter.

I purchased a 2GB Sony card, a 4GB Sandisk card, and a 4GB Kingston; and
tried them in all combinations of two different XP machines, one Vista, and
one Windows 7 machine. All give me the same errors - consistently.

I use MiniTool partition wizard, and have also tried partitioning to FAT32
using Linux to partition when needed.

Windows 7 often gives an error when doing the "Relayout!", but works the
second time around. The odd time it does work the first time around, I get
this message when I try to fuse:

"Fusing Disk 1 Error(Readonly Media?): The request could not be performed
because of an I/O device error."

Otherwise on this and all other machines I get:

"Fusing Disk 1 Error(Readonly Media?): The system cannot find the file
specified."

or more commonly:

"Fusing Disk 1 Error(Readonly Media?): The system cannot find the sector
requested."

After getting these errors I confirmed that the card is not write protected
by successfully copying a file to the disk and subsequently deleting it.

I am at wits end with this - any help would be greatly appreciated.

Thanks!

Problem solved. Used My Linux machine to manually write the image with dd
command.

Exclusiv, can you reply back with some steps on how to do that with the dd
command.  I am having the same issues.  I am not too familiar with linux dd
command.  Thanks.