Wierd, can you send me that page: category_manage.php so i can look at the recordset? :)
I added a Test Cat for main and sub, and it loops it, but that you already knew! :P Something is overlooked in the recordset i think and the repeating region.
btw whats the name of the menuwriter folder for your first working menu? Is it cssmw2?
There is a folder called menu_content (maybe its the CSSSculptor that creates that one).