ok, I just tried packing all of PCS's external dependencies into a zip, and it came out to be more than 40mb, if I upload that would you be willing to download it and the source compile it on your end and try to run it in debug? if you compile it I garentee it'll run.
and kazan I just noticed a bug with our BSP compiler, think about what would happen if a polygon landed exactly on the split between two bboxes. like you might get if you converted a cube and it split it in half, you'd have 4 polys that were on the split plane.
another clue our bbox functions use point<=min && point>=max.
if you still aren't seeing it, in this unusual but easy to reproduce situation, there will be polys that are consitered to be on both halfs of a split, or in both child bboxes, the way our code works this will result in duplicate polygons.