Hi John,
Yeah, we did use the Beaglebone+Wifi Cape as our starting reference, and have been able to prove our software design with this setup. We then decided to be 'smart' and run the SDIO at 1.8V from the main processor on our own custom board, negating the need for intermediate voltage translation chips between the AM335x and the Tiwi-R2 ,which were (apparently) only required because the power feeds to the processor on the beaglebone are hardwired with 3.3V - but we have been unable to get this to work, and we have been unable to find anyone else who has succeeded with this configuration, or to confirm whether it should/shoudn't work.
So as you suggested, we are in the process of duplicating the beaglebone/wifi circuitry on an new board spin with all of the additional circuitry that this entails.
Regards,
Andrew.