I seem to have a fuzzy recollection of encountering similar problems when I was doodling with the RTS example, but I can't recall how exactly I coped... Maybe if you upload the file I'll take a look and try to solve it? You can use a site like filefront or mediafire or something, then post the link here.
As for the bouncing part, unfortunately I haven't been able to come up with a decent solution myself. Making them solid seems to screw around with their pathfinding when they're on the move, so as far as I can tell the default system seems to be the best. But if anyone else can has some good suggestions I'm all ears