OK, I just got home from the clients house and I'm feeling pretty good. I tried the electrical tape thing....didn't work, I tried swapping out the IR emitter with a Niles emitter....no good. I even brought over my demo mx-3000 and mrf300 and swapped those out......no good. The homeowner had another 8300HD cablebox and swapped those.....didn't work.

Here's what did work. I moved the RF antenna about 20 feet away from the closet, rack, and components. I used the extra wire URC gives for the antenna and extended it with cat5. The RF output is set at about 1/3 on port 4. Also had to fool around with the different RF channels. We tried 3, 9, F and ended up with A. The IR emitter is right in front of the IR sensor on the cablebox. With this I seemed to get fairly consistent operation. I left my clients house feeling pretty good. I just want them to use it and make sure we're good.

Thanks everyone for all your help.
Rob