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...today playing with back cover wrapping 😄

It is not really important - you may reformat the card later.

so should i insert it into the phone first to format? or first into the testing program on windows.

I think it is better to let the phone do it. However, for testing, you may use any filesystems under Windows, but it is important to go through writing and also reading the whole SD card and check if everything were okay.

Got an answer from support today asking for a couple more pictures of my phone. Was probably overthinking if I should reduce JPEG quality for filesize or send the hires original. Sent the original sizes using several mails anyway. 😅