Hi Michael,
  Thanks for the info; lets see if I can answer some of the questions:

To clone a card the challenge is that any 2 cards aren't necessarily the
same length - any 2 8GB cards might vary depending on the cards ideas of
how much space to leave for bad sectors, how they organise thing and the
general phase of the moon.

If you have really absolutely identical cards then cloning them using the whole 
device (/dev/mmcblk0) should work,
but if you want to clone so you could stuff it onto another one then the only 
safe way is to make sure the partition
is a bit smaller than the whole disk (to allow for the next card to be a bit 
smaller), then when you partition the new card
make the partition on the new one exactly the same size and then clone the 
partition.

Now, to your errors:
  1) well it shouldn't hard hang
   2) and if the card really is large enough for your image then it shouldn't 
run out of space - check that the size shown in /proc/partitions matches the 
size of your file.
  3) You shouldn't get that task hung error
   4) If you're getting any I/O error's prior to ejecting the card then the bit 
to include in this log is the set of stuff just before the first I/O error.  
Errors after ejecting the card are well, expected!

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https://bugs.launchpad.net/bugs/975305

Title:
  dd writing to an SDHC /dev/mmcblk0

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