Now this might have been obvious to folks, it was not to me and I found it when I was retrying the whole process again.
With 32gd card -
1) Formatted the card in the camera
2) Not sure if this formats the boot flag so Quick Format it with the computer.
3) Extract ML and copy the extract + Boot fir file to the card
4) EOScard to update EOS Dev and boot flag on the card
5) insert card in the camera, start the camera
6) Try to update firmware, the camera says battery is too low to update (Previously at this step, after firmware update, I would get message about Magic Lantern Rescue and to remove the battery)
7) Exit Menu... groaning that I need to charge the battery before I try this again, I press the trash can button
8 ) and ML Loads!!
Ofcourse thinking about it it makes sense. The BOOT fir file only flips the boot flag on the camera, this has already happened. so from the second card onwards, I dont need the BOOT fir file or the firmware update process. I only need the card as bootable and ML on the card.
With 32gd card -
1) Formatted the card in the camera
2) Not sure if this formats the boot flag so Quick Format it with the computer.
3) Extract ML and copy the extract + Boot fir file to the card
4) EOScard to update EOS Dev and boot flag on the card
5) insert card in the camera, start the camera
6) Try to update firmware, the camera says battery is too low to update (Previously at this step, after firmware update, I would get message about Magic Lantern Rescue and to remove the battery)
7) Exit Menu... groaning that I need to charge the battery before I try this again, I press the trash can button
8 ) and ML Loads!!
Ofcourse thinking about it it makes sense. The BOOT fir file only flips the boot flag on the camera, this has already happened. so from the second card onwards, I dont need the BOOT fir file or the firmware update process. I only need the card as bootable and ML on the card.