XIII:Which tool did you use or was it rather like "we already try everything this is just the last stupid thing that we could look at before smashing the server..."?
Yup - something like that. The turning point was when I noticed that the same thing was happening when I took a static HTML cut of the page and tried to load that. It kind of ruled out anything happening on the server which had been our point of focus. So I started removing external file references (JavaScript, etc) and when I finally removed the CSS, the world came alive.
Talk about a pain in the ass! Hopefully, though, this will be of use to someone in the future.
When I look into it, CSS expressions (which were once considered a pretty clever way of getting around the inadequate CSS handling of IE6) actually cause it to hang in lots of environments. So I'd advise everyone to avoid them altogether. They're IE specific anyway, and IE7 is compliant enough that you don't need them. Sad thing is that statistics are still telling us IE6 is the most popular browser on the planet, so we can't disregard it just yet!
Cheers!