I figure this summer I'll try to redo it.. (3 weeks and counting until I'm home)

Things I'll do differently:

a) document everything so when I fail someone else can give it a shot without reinventing the wheel
b) finish that tileset compiler first..
c) start the level editer as STRICTLY an editer of existing (working) levels and start with abilities I know I can get 100% right like tiles.. then events.. working my way to figuring out the sections which could cause problems like missing sounds??
d) ask more people if they want to help out? or take it over if they're so inclined?

Personally, I have no idea about the sound problem.. never heard of it before either, but whatever. But the opening and resaving screwing around with things doesn't surprise me. Some sections are probably hardcoded into the editor and overwrote the real data.. it's a very stupid way to do it, but I wasn't really involved in that (so I'm not actually sure that's what happens, but whatever)