I only looked through your steps quickly, but I'll go through them in more detail (maybe try to make my own anim using your process). But it looks mostly right. Two things I see though:
The origin should be 0, 0, 24, not 0, 0, 30
Assimilate generates the animation.cfg based on the anims you have... do any of you have the original .xsi files and .car file? If so, you might be able to use your new XSI with our old ones (now that the skeleton matches) and build the skeleton properly, like we did...?
Michael Chang Gummelt