Sorry, I can't offer a solution but I may be able to add more detail to the problem. I'm having a very similar problem with one of my clients' systems. I too have recreated the OST file with no luck. I also synchronised each folder seperately until I found the one that was causing the problem. I then created a new folder and moved the emails from the troublesome folder to the new one, and then deleted the old one. When I re-synchronised, I found the same problem with the new folder, so I can now rule out a corrupt folder.
Next, I created another new folder and moved batches of emails from the troublesome one to the new one, re-synchronising as I worked. Eventually, I managed to move all the emails across and the new folder synchronised without problems. Notice that I havn't found the 'problem email' I was expecting to find.
Now the whole system synchronised without a problem, and I really have done nothing. However, one day later and the problem is back. I had not deleted any emails during this process, so it doesn't seem to indicate the size of the folders to be a problem.
I hope this provokes some thought within those highly technical brains out there! I'm a general IT consultant and so although I understand the general principles of the exchange system, I don't profess to know all the ins and outs of this particular system, so please explain things simply if possible!