I tried the business card trick with no luck at all.
So last night I tried reformatting the card in a (Windows 7) Command prompt to FAT32. After two hours of progress, it told me the volume was too large for FAT32.
This left me with an essentially unformatted card. Windows couldn't read it. So I popped it in the phone. Phone said "SD card is not readable" or some such, so I let it format the card.
I then added just 4 albums worth of songs (Laura Marling, if you're interested!). Since last night I have been listening fairly solidly, and have had no incidences of SD card problems so far. I even tried shaking the phone quite vigorously, I've walked around, nothing is making the card hiccup right now.
This is still early days but it looks good so far...