Thanks for providing the information via pm/irc, the bug found should be fixed. If you could re-test and get back to me that would be great, thanks.
Start from step 4.
Definitely progress, the transaction now validates after signing, but still TX rejected when broadcasting. I've PM'd you the signed tx hex.
You've not mistakenly signed the transaction twice, but with the same key have you??
I've run 3-4 tests this morning, everything is working fine from my perspective, could you get in touch again via IRC so we can go through it step by step in an attempt to reproduce this bug.
Thanks