Do you have a gunny friend with a similar amount of experience who might hands-on with it for you? I find it's pretty common that when one guy hits a wall, a fresh set of hand and eyes can do wonders.
Best of luck with it, regardless. I've never heard of anything like what you describe, so it seems likely that it's either a simple fix you're not snapping to for whatever reason or it's a nightmare that will need major mothership intervention. But . . . Occam's Razor - see if you can have someone else figure it out before you go to all the trouble.
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