I still don't think I've found a CF card that works 100% perfectly with the SNES Powerpak.
The first one I tried was a Sandisk Extreme III 4gb, new out of the box. I got an error message like "$01 CF Card Error", and it wouldn't boot at all. I tried formatting it in Windows XP in fat 32, and that did nothing to solve the problem. Ultimately, I returned that card back to the store, and I got my money back.
I was walking around Target a few days later, and they had a cheap Lexar 4Gb CF card for about $15. This is what I'm using now with the Powerpak. This ran games right out of the box, but everything was initially very glitchy. The text in the game selection menu appeared corrupted at times, and games only loaded and saved properly some of the time, but not consistently.
The next thing I did was open up config.txt in the POWERPAK directory with the mappers, and change DMA=1 to DMA=0. Everything has now worked perfectly for the past week or so.
So, it seems some CF cards work, and others don't. It's really hit or miss. I would still probably be happier to have a faster card that works even when DMA=1. My technical knowledge is very limited, but I understand DMA is a memory mapping mode that flash memory uses to take advantage of better read/write times.
If changing this config.txt DMA setting only affects the time it takes to load a game from the CF to the Powerpak memory, and has absolutely nothing to do with the quality of games running on the Powerpak, (my current understanding) then I probably don't need a different CF card, and my current setup is fine.
Otherwise, I would be tempted to take advantage of that Amazon sale if it still existed. I don't think Lexar is a great brand, and the performance of my CF card isn't amazing or anything. It's probably likely to fail at some point.