Savage - did you solve your problem ?
One thing I didn't add at the time, as I didn't ant to further complicate the issue - but will now as it may yet help.
LEDs described as Infra-red, come in two wave lengths - pure IR, which is 940nm wavelength, and 850nm - let's call them the 'fatherless'
version. I always prefer to use the 'fatherless' version, as these also respond to much of the visible light spectrum, whereas pure 940nm ones do not.
I also find that the 850nm ones are generally more sensitive. Check out this EBAY listing for
940 and 850nm LEDs.
Check every time you hookup that the LEDs that they are lighting. In my experience, hooking them up the wrong way around at correct voltage DOES sometimes blow them up. The only time I have had to repair my light bridges is a couple of guys who hooked them up the opposite way around when they couldn't see white light, and cooked one or two of the bank - requiring me to replace those, and send them a second instruction sheet about looking at them through a digital camera or phone, not with naked eye (although the 850nms conveniently glow a pretty pink to the eye if you look directly up their spout.)
There seems to be a dearth of 850nm 3mm diameter photo transistors on EBAY at present. No idea why. I usually buy 10 packs from a multitude of offerers. There are some stupidly expensive UK sources, making about a 50,000% markup......