Thank you so much, [MENTION=14603]VSZ[/MENTION]! Did some more investigating based on your suggestions and logged my findings below.
I'm running with an Intel Core i5-4690K Processor (3.5 GHz) w/ a debug build. My game tick idles at 5-6ms without any path solver queries, and then it spikes to 18ms when it fails to solve a path query with only 200 iterations set for the max. If I set the path solver iteration max to the default of 500, I spike all the way up to 50ms for the game tick when it fails to solve. Yikes!
This verbose debug is GREAT! Thanks so much for the heads up there. I noticed that IsDirectPathLineSweep is returning false in ADonNavigationManager::SchedulePathfindingTask b/c it's hitting the player pawn's collision capsule. Is that expected? Here are my collision settings for the collision capsule:
https://drive.google.com/open?id=0B9...UFtWGc1UFlFTEE
If I set the capsule to "No Collision", all of my direct line pathing succeeds. So, I assume my collision on the capsule is a major culprit w/ regard to my issues. What have a screwed up here? O_o
YES! This fixed the hang 
YAS! increasing those "tweakMagnitudes" values cleaned up the remaining failures when it was trying to path around more complex landscape geo. I made them 10x bigger cause the scale of my world is so much larger. Maybe worth exposing those for the user to edit instead of hard coding?
Yeah...that's weird. At least I have a fix for my hang and now that my path finding isn't failing on the time, those instances where it was hanging aren't occuring.
Thank you so much, [MENTION=14603]VSZ[/MENTION]. I hope I can pay you back one day for all your help
Originally posted by VSZ
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Originally posted by VSZ
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https://drive.google.com/open?id=0B9...UFtWGc1UFlFTEE
If I set the capsule to "No Collision", all of my direct line pathing succeeds. So, I assume my collision on the capsule is a major culprit w/ regard to my issues. What have a screwed up here? O_o
Originally posted by VSZ
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Originally posted by VSZ
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Originally posted by VSZ
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Thank you so much, [MENTION=14603]VSZ[/MENTION]. I hope I can pay you back one day for all your help

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