Thanks! The proof of the pudding will be when I try making a varity of easy<-> hard levels, and speed/puzzle/technical types.
Right now the only way to crash is to hit the riders head, but I may alter it to allow crashing when hitting the bikes wheels/body hard enough.
Still - I wont waffle on about the game here (Started a thread for that [wip] Wheelz2 (Physics Bike game) - now in Early Access! - Work in Progress - Unreal Engine Forums will update with pics and new videos later)
I think for the improved terrain collision, my suggest hack would really help - but what really needs to happen is a physx update.
Perhaps (only if CCD is enabled?) there could be a forced collision check with the objects our wheel collided with in the previous frame, fixing position as well as velocity before performing the standard collision checks.
But that sounds rather sub-optimal, and is not only a topic for a different thread, but also probably a different forum!