Dead Z - Cannot Flash ROM - file corrupt?

I was using the old Sharp ROM on my Z and decided to flash it to the Openzaurus 3.2 (which I have used before without problems).  I downloaded the 2 files, I chose the 48/16 image.  I renamed the zImage file and proceed to flash my Z.  Everything seemed to Flash okay but after I pressed reset and turned on my Z I got thousands of errors stating TAR Bad Header and then thousands of other errors stating ERROR /some/file/  cannot open the file.
Then I get an INIT Id "ln" respawning too fast disabled for 5 minutes then it starts all over again.  I suspect the download somehow became corrupt.

I tried reflashing my Z back to the OSPACK but that is not working  either.  I have reformatted my card (FAT) and tried numerous times but each time it will not flash.  Both lights light up for a few seconds then disappear and I am unable to get the ROM re-flashed.

Any ideas how I can get a working Zaurus again?

Thanks,
Nick