I have two open threads right now and I think both were resolved in one swift move:
I mentioned before we use a co-domain. When I switched the domain from domain1.com to domain2.com on the basis tab in the web interface, all my problems went away. The catchall was moved to the correct account, all the aliases and bad email accounts started working, and I just might be able to spend the weekend at home instead of the office!
So....what does this mean? Should I keep this method in my back pocket as a "fix all"? What does ispconfig do to the user tables and db files when you swap the main domain in a co-domain configuration?
Thanks for your follow-up I am breathing much easier now.