Randy
nice work in your build and debug.?
given the paddle function to be working, and a presume to send good CW via the transmitter, hard to fathom how manual keying can't be working - with an appropriate voltage read there.? given your pot experiment, I presume you tested it down to zero and not found any manual keying.? I suggest manual keying with a piece of wire, to confirm you don't have excessive corrosion on the key contact - then you could try substituting a resistor for the 4.7 k resistor (also measure that critter).?
A firmware copying issue seems so unlikely with everything else working.? I really think the issue is hardware.?
The sidetone on the v4 is dreadfully loud.? I don't recall any related changes in v5.? Therefore I suggest that you consider this mom developed by a ham in my local club -- I did it and it works wonderfully.?
Curt