Jeff --

My head is spinning... Attach a couple of sample images (zipped) so I can see them. I understand your frustration and the ways in which you've tried to succeed but what you're experiencing is vastly different from the experience of others, so I have to guess that it's related to something about your images. Sometimes if the pointing is way off, with PinPoint operating at the hairy edge of the envelope, it will act weird like that - by lplaying with the parametrs you're creating "just the right environment" for it to find a solution. Anyway, the images will help. Include the plate scale (arcseconds/pixel) please.