http://gumstix.org/create-a-bootable-microsd-card.html is the really long way to do it. It does work but there is a script that makes it much easier. Follow the instructions here: http://wiki.gumstix.org/index.php?title=Android_Prebuilt It is a more fool proof way of doing it. If you are using the Overo Tide, you will need to modify the bootloader as it cannot save the boot config to the flash (there isn't any); other boards shouldn't have a problem. Let me know if you are still having problems after this.
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