Hi Lon,
Nice to see you here again.
Anyway - I may be way off here and the best people to give you a definative answer may be TGC - this problem I beleive to be similar to that of enemies not recognising terrains properly. I think its an engine issue related as you have said to raycasting - as in order to do that properly then the engine must recognise and object as one it can see properly.
Now inside FPSC - enemies would normally recognise floors of all the various default kinds because they are segments - and as you may know a segment has many internally recognised code settings which you can see in a segments script file which indicate to the engine which part is the floor, walls etc and how entities should react to them. Any other user inserted floor which is not made up correctly as a segment and specifying those various parameter settings for the engine to recognise means that it does not recognise a floor as such and correctly.
What I am saying is check segment scripts out and you will see why this is probably the case - any etities script file has no way near the same code for the engine to read. The answer then is to try and find a workaround.
The static entity bit is the problem FPSC expects floors to be segments and have the appropriate info to send to the engine to say it is such - thus the difficulty with entities falling through or not walking over terrains properly.
At least it may be allied to this situation - as said I am really not sure but I do know that terrains are a problem in this way - enemies cant really follow the contours as they obviously dont trace to a terrain surface correctly. Why not is anybodies guess I would think as - as you have pointed out if say you make a single floor tile entity to cover a hole the emeny does not fall through it - and they can certainly move over other kinds of static entities as we know.
One might be tempted to suggest that the poly size may allow enemies to fall through but I dont think that alone is the case - theres more involved going on than that I recon.
Anyway all that is not really much help I know - when I get back to terrains I may find an answer but it dont look promising as we dont seem to have enough script control over physics and gravity settings to control enemy entities movement over floor surfaces. We only have things like nofloorlogic and a few other script command weapons at our disposal.
Perhaps some else has found a solution - I do hope so.
If you cant find one I suggest you kinda think segment and see if any workaround comes to mind - otherwise ask someone in a position to answer such technical questions realting to the engine at TGC. You cant however make such a large segment so what I am saying is theres just something to learn from how FPSC uses segments as floors.
I had experimented with some mixed commands such as no gravity, set gravity , nofloorlogic, physics weights and so on in various combinations for enemies moving over terrains correctly but the best I could do was to get them to move but always slightly upwards so eventually they kinda stick moving 1 foot above the ground continuously which looks silly. I could not find a combination of commands to force them onto and follow a terrain surface exactly - still working on it.
But you are correct theres no trace to surface so a forced workaround seems to be the only way. Hopefully someone will crack it if not TGC.
"I am and forever will be your friend"