Looking through all the posts on the net it looks like I shouldn't have been able to re-open ANY gcode in Cura.
This is really strange because I had been until yesterday. I am sure I was and it was a regular part of my toubleshooting print issues. I would save it to the flash card, try to print, see an issue, stop the print, re-open the file directly off the card and make changes to the print setup and re-slice.
Was I just lucky that my software load had a bug and it got fixed? That's a shame because it was nice to be able to just overwrite the filename of the gcode instead of having stl files and gcode files on the same card.