Thanks for the suggestions.
The camera is not plugged in when I'm getting the error.
I tried popping the battery to make sure the camera was getting a full reset and letting the camera sit powered on for about 10 minutes to let index complete (there's only 95 images). Same error.
I also tried removing the images, so there was nothing to index, removed battery, powered on, let it sit. Same error.
I opened a ticket with Flir, their only response was "return it for repair" I'm trying to avoid that.
I did notice that none of the "system files" (flir.db, postlog.txt) have been updated on the flash since I did the format. I did replace the original files but that didn't help. The camera is acting like it can't find or mount the flash.
I'm really hoping that re-flashing will fix the issue, I just to get my hands on that update package.
Thanks everyone.