Hi,
It is really hard for me to say, when I do not have any code to look at. While I do not, I can only reply generally, and everything I say will be pure guesswork.
What I would do personally in your case is either start removing some controls and try isolating the problem, or I would create a new form, add an instance of the problamatic controls to that form and view the designer generated code and see what properties are being set, if all is at default. Then I would compare those settings to the ones in the problem form and see if you spot any differences. There are some differences in designer generated code in version 6.4 compared to earlier versions, and some of them might conflict.
One particular one that you may watch out for is a control that both has a non-empty docking setting as well as non-empty anchoring setting. That may cause problems in some cases.
You could also create a new testform, then start copying designer generated code fragments from your problem form to your new form until you find what code fragment introduces the problem.
This can be a very long and boring task, but as you can't spot it yourself, I don't see what other option you have.
Palli