Well I am trying a custom Intersect Ray script, similar to the one the max engine uses. We'll see how it works. So far it is acting strangely, but I can return a list of the exact faces which are intersected by a shadow, and I can modify it to get both faces which are hit on the normal side and on the back side. So far, I am trying it with just the normal side. What I am left with after 1-5 iterations is a mostly fragmented model mesh, and then a clump of faces it claims all cast shadow on each other. I highly doubt the math is right, because at least one of those faces, especially the lowest one, should drop off every time I run it, but it doesn't. I could just be wrong. Anyway, it it telling me to explode that remainder clump, but I am not.
First export results in a crash of the toolset, but I didn't check why yet. I suspect it is the naming scheme getting really long as it iterates.
Second export with shorter naming scheme seems to do the trick. Unfortunately, without breaking the remainder face mesh, I see zero improvement in shadow quality over previous methods on tall faced meshes. Improvement on short faced meshes is spectacular!
Third export with better naming scheme and remainder of faces exploded gives no improvement, is actually detrimental, showing face seams as lightly dotted lines, and gives a serious performance hit. Checking the mesh files shows some tvert errors. Next.