Clearing cache/dalvik doesn't help -- phone reboots to "optimizing apps" but gets stuck on "starting apps". If power cycled, it gets stuck at AOIP logo (it's an AOIP rom)
Tried reflashing the rom (AOIP-2.0-ancora_tmo-OFFICIAL-20131006) -- same result
The internal SD card appeared to be out of space -- mounted it over USB (thanks to CWM) and cleaned it out so it's at ~60% now.. but the phone still doesn't want to boot!
Created a backup with CWM and wiped the data (after removing the ext sd card) -- phone boots up properly!
Restored from the backup -- phone doesn't boot
What else can I do?