OK, got it...man...combo of a few problems.
First, the original files on the win2k server were all lower case, always have been. Most likely the FTP program I used didn't preserve case, but win2k ubb doesn't care so it was never an issue. I fixed all the dirs and files during the transfer so that was ok anyway.
However when I did the rebuild forum stat files after the move, it created copies of all the Forums dirs, with the correct case...but for some reason the stupid cache on the FTP program was telling me the threads also propagated into the duplicate dirs...but they didn't. So I deleted the 'new' dirs and manually renamed the 'old' ones.
The Catagories thing is still a bug however. I was able to create deplicate catagories and use them, but now have a set of catagory numbers that will never be used because anything using them is not visable.
___________________
Webmaster
www.sbtontheweb.com