John,
I finally got the defective IRF-6 back from my customer. Unfortunately it is S/N 020-005243 which blows the production run theory, maybe?
I know this is a defective vs. RF interference as it worked great for about a month and then faded to no reception distance at all. As you suggested, it would be worth our while keeping a running log, but so far it looks random.
Bill
www.homeautomationnet.com