I have initially failed to install on a Large or LBA drive, so I picked largest CHS values. If your SD2IDE is fully software and uses .img as backend you can try booting the image I left on the google link. If it's 1:1 to SD card it's going to be too large.
CF cards are native IDE and ofc you can under-provision it with 504MB geometry.
Biggest issue with real hw is SCSI reliance for larger drives and CD ROMs, unless you have ancient 2x Mitsumi+controller combo...
Fastest way to get this to real hardware is to install on emulator, install distribution sets but no configure, and then dump the image to a CF card. The real PC should boot it, the disklabels should match.