After i blend all my objects into one polymsh (to minimize file size), add the duplicate for the collision, munge, and go live, it seems that the collision geometry only applies in a few select spots. Any ideas or fixes?

If you're using an exact duplicate for your collision mesh, then there's no reason to have a collision mesh. One will be created when you munge. But, if you are using a low poly version of your mesh:

1. check your normals, make sure they're all facing the proper way
2. make sure your model and the collision geometry's transforms are frozen, and that the collision geometry is parented to the model
3. make sure your odf specifies collision geometry ie SoldierCollision = "CollisionMesh"
4. if you've checked all of the above and that doesn't help, try making the collision mesh just slightly larger or smaller than the mesh, like scaled 1.001 or .999