Download and install the latest RCE SDK.
Create (mkdir) SD partition mount points on host as sudo
/mnt/sdX1
/mnt/sdX2
/mnt/sdX3
/mnt/sdX5
/mnt/sdX6
/mnt/sdX7
Where X is the device letter, such as /dev/sdd or /dev/sdj
This will depend on where your host mounts the SD.

Populate SD card with SDK contents as sudo (assuming a SLAC host)

Execute the mkrcesd command.
sudo mkrcesd sdX d[p|t]m --sdkroot <path_to_installed_sdk>
For example DPM:
sudo mkrcesd sdd dpm --sdkroot /u1/reg/dune/rce-sdk/V1.5.0
Now you should have a bootable SD card.
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You can mount /dev/sdX3 to access the ArchLinux partition and add any application specific content there.
You can mount /dev/sdX1 and overwrite fpga.bit with application specific firmware bitfile.
If auto-loading your own bitfile, you have to create a custom uboot.env and copy to /mnt/sdX1
mkubootenv <full_path_to_output_dir>/uboot.env 00:00:00:00:00:00 0x1 sdboot_linux loadbit=1
(Yes, the mac address should be all zeros if using the latest eFUSE enabled rces)
cp uboot.env /dev/sdX1


A few notes of warning for SD card readers.

The devices do not always show up when an SD card is inserted.
Before you try to make a card, be sure the device is present by executing lsblk
If you don’t see it, try to reinsert the SD card.
If that still doesn’t work, you have to reset the USB bus for that reader.
First, find the device on the usb bus
> lsusb
Bus 001 Device 001: ID 1d6b:0002 Linux Foundation 2.0 root hub
Bus 002 Device 001: ID 1d6b:0001 Linux Foundation 1.1 root hub
Bus 003 Device 001: ID 1d6b:0001 Linux Foundation 1.1 root hub
Bus 004 Device 001: ID 1d6b:0001 Linux Foundation 1.1 root hub
Bus 001 Device 053: ID 413c:a001 Dell Computer Corp. Hub
Bus 001 Device 003: ID 1a40:0201 Terminus Technology Inc. FE 2.1 7-port Hub
Bus 001 Device 005: ID 058f:6465 Alcor Micro Corp.
Bus 001 Device 006: ID 058f:6465 Alcor Micro Corp.
Bus 001 Device 007: ID 058f:6465 Alcor Micro Corp.
Bus 001 Device 008: ID 058f:6465 Alcor Micro Corp.
Bus 001 Device 009: ID 058f:6465 Alcor Micro Corp.
Bus 001 Device 010: ID 058f:6465 Alcor Micro Corp.
Bus 001 Device 011: ID 1a40:0101 Terminus Technology Inc. Hub
Bus 001 Device 012: ID 058f:6465 Alcor Micro Corp.
Bus 001 Device 013: ID 058f:6465 Alcor Micro Corp.
Bus 001 Device 014: ID 058f:6465 Alcor Micro Corp.
Bus 001 Device 015: ID 058f:6465 Alcor Micro Corp.
Then reset the device using usbreset
Usage: usbreset device-filename
 i.e.: usbreset /dev/bus/usb/001/004
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