Rob,
I think you came to your senses. I would not tear your tank down without first trying to find the source of the problem. It may be something that happens again once you start over.
You stated you make your own RO/DI water. Try testing that water for PO4 and Silicates. I know your TDS measures 0 but it's worth a shot. Then test your fresh saltwater as well. Something may have happened to your salt mix and it may be introducing some bad stuff.
I guess I'm old school and bucked the trend of the DSB panic and still believe in the utilization of one. So, if you still have one make sure it's healthy with worms, bugs, etcs... If not purchase some detrivore kits from different web dealers.
You might tweak your skimmer and make sure it's still functioning properly and pulling stuff out.
Your LR is fine. You need to find the source of what the algae is living off of. In all honosty, something may have happened at some point and you are going through another cycle.
When I had this problem a while back I purchased a Red-Lipped Blenny. These guys are very similiar to Lawn Mower Blennies and will mow hair algae down. It is definately an option. I've never had one, but urchins are reported to do a good job as well.
Check your flow too. It may be all around the upper water level and not circulation well around the rocks. Just a thought. /shrug
Don't give up man. I think starting over will be a bigger pain than trying to battle the algae IMO!