I suppose I should take down the sd recovery from post #2 since it's causing hassles. I'd like to figure out what's going on though. Strange that it works for some but not others. Variables: different partitioning software, different sd cards, different phones. I guess using the wipe script is less hassle anyway though. It might be better to have individual wipe zips for each partition, also zips to mount each partition from recovery. I can make those.
As a test, I plugged my sdcard into my linux system and found, as dman861 reported, that the last partition on the sdcard had a type of unknown. I reformatted it as ext4 on linux and now, the phone boots into cwm instead of just displaying the cwm screen and then continuing to boot the phone to android. I rechecked the sdcard on the linux system and the last partition remains properly formatted ext4.
I have not updated or changed anything since the last time I tried, so the only difference was the formatting of the last ext4 partition on a linux system instead of minitool partition manager on windows 7 x64 which may not able to create these four primary partitions properly. After all, according to windows, you are only supposed to have one primary partition on a disk - LOL.
I used gparted on linux, so using the live CD or live USB version of gparted.org might be the way to go if you are on windows.
My phone is the Virgin model.