The JIRA report came back as not being a bug. The developers said that the correct way to handle this setup is to use the first fix I posted above. You shouldn’t directly line trace off a a surface normal, you need to add that small offset to keep errors from happening.
However, there still seems to be issues with older converted projects. I believe recreating them in 4.6 will fix the issue and upgrading from there works correctly (tested with our latest internal build).
Here is a tutorial I posted with those changes.