The simplest explanation would be the configs are not as identical as you think they are.G1UYZ wrote: ↑Tue Sep 15, 2020 8:21 amI retested the setup again using the same memory card as I use in the pi zero w and it works which is just weird. The card and content is identical to the one I used before only it had not been used with the Pi zero and hadn’t been set up to use WiFi. Strange really.
You could back each of them up and then use a diffing tool to compare each zip and their contents line by line.
Its also possible the 2nd SD card is corrupted. I ran into a brand and specific size of card that my RPi's absolutely hate and start putting garbage into the middle of files randomly. Check your brand against this list.
If you want the easy fix, I would would backup hotspot 1 and restore that setting on hotspot 2, and change a few settings.