Rebuild Esxi on existing SD card?

[Archon45]

We are running ESXi 6.0 on an SD card on a Dell server for testing but it appears there are issues with the SD card after a series of power failures:

• ESXi reboots but new settings are not saved after reboot(eg: cannot change root password, list of VM's can be changed but is not saved)
• bootbank is not found

Looking around the net suggests the settings are not saved as any changes are probably saved to a tmp file

Is it advisable to rebuild ESXi on the same SD Card or get a new card?

Can you relocate/rebuild ESXI to a more durable storage medium like a USB drive?

Is there a knowledge base or guide on how to rebuild ESXI?

[NateNateNAte]

If it's just a single VM, then you probably can rebuild, but I'd recommend a new SD card.  It sounds as if some of the SD card storage is getting corrupted - which does still happen with SSD devices.  You could do the same thing on a USB drive, but it depends on the HW security settings on your server and in particular the boot order for the server.  

[Errock07]

when u use a ESXi iso upgrade ur system, there will show u 3 options.
install and preserve data
install and overwrite data
upgrade

for testing, i think u can upgrade ur ESXi
but 6.0 6.5 and6.7 all out of support.
maybe u can install last 7.0u3(can not upgrade direct from 6.0,choose install and overwrite)
don`t forget use Dell oem ESXi iso
Usually SD card won`t damage by power failures , only data will .
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