I actualluy think the pins inside are not straight therefore bad contact, somehow it just affecting my R4. I will try fixing and will let everyone know. Tnxxxxx.
I tried a few layers and many layers but still the one DS lite cannot see the R4 card while the other does, and that DS can run non-R4 cards without any issues.
2 original R4, both work on the first NDS lite but both do not work on the 2nd NDS lite (that is the NDS does not see them).
I did try to use the latest OS 1.18. No good. Tried using a piece of paper to ensure the card is well inserted - nothing. Original cards work well with that NDS lite...