I do take a good note of everything before I take it apart and label if neccesary. I've seen switch legs brought to the panel, in fact I did a pool light this way once after the original switch leg went bad under a slab.
There were no white wires anywhere but on the neutral/grd buss. Even the 240 loads were red and black. Take note where I said all works fine when hooked up, I just can't switch the breaker on with the 3 way on at the same time. Once the breaker is set, you can switch the 3 ways all day long with no problems.
I have another day to spend there, I will examine the 3 way wiring.
Coastal, I am having a hard time picturing your scenario. And why everything works fine once the breaker is set.
[This message has been edited by BigB (edited 01-03-2005).]