One step closer.
After a phone conversation with one of the PSoC reps, I was asked to remove the bootloader from the code and test it.
Well, it works perffectly in both the SMM and the LMM.
So it's some crazy interaction with the bootloader and my code???
Unfortunately I need the bootloader code as the job is in Oz and I'm inn the USA and I need to be able to download code into it in case of revisions.
So still all up in the air but it got really close to me having to fly to Oz to sort this shit out.
I may have missed that bullet. At least I hope so. I really can't afford the time to do that.