An archive is an exact replica of the card, not just the media files, so it behaves like the card. It can either be creating by copying the card content to a hard drive, or using the archive function in FCP, which encloses it in a bundle.
Even if I get it to copy the media into library it does not work. It ONLY works if I do it straight from the card.
I don't know what this means. Are you saying that if you make an archive of the camera card on your hard drive, you can't import from it? That you can only import from the card itself? That doesn't sound right. What are the specifics of the camera and the format that was shot?
I have heard talk of SD card clone utils but have not found any.
You should be able make a folder on the drive, select all the contents of the card and drag them into the folder. Or you can use the FCP archive function in the import window.
The other issue with cloning is I have other stuff on one of the cards I don't want to archive (as the archive is going to client).
I don't know a way around that I'm afraid.
P.S. Actually there may be a convoluted way around that. If you use FCP to import the media into a folder on your hard drive. You can use a utility from Andreas Kiel called VirtualCamCard http://www.spherico.com/filmtools/ that will enclose the media in a folder structure that behaves like a camera archive.