You know what's worse than having things figured out and not sharing? Thinking you have things figured out and finding out through painful, burning failure that you in fact do not.
This is going to be a bit of a long message. Please forgive me, I am frustrated and love the sound of my own voice.
First off. I need to come clean. I have OBVIOUSLY taken this lesson a lot further than I need to. I fully realize that I am asking to learn things above my pay grade as far as the TAO lessons go.
I've attached a .zip of the project file as it is right now. I got a lot further before the wheels came off the bus last night but the result was so bad it damaged everything that came before it and so I had to go back to this point and try again. So far I've been at Lesson 6 for over double the alotted 6 hour time frame; and not happy about it either.
I watched Robcat's tutorial on transitioning from a preset action to posed movement. I'm a little disappointed. Not in the tutorial, I'll talk about my issues with that in a minute, but with the program itself. I cannot believe there isn't an easier way to transition a model from an action preset to posed action. The steps you have to go through to continue the action are; considering the ease of use in much of the rest of the program, shockingly counter intuitive. You should just be able to select a keyframe, select the action in the project workspace and just hit a button called transition to pose or something.
Ok, now my issues with the tutorial. And I should emphasize these are my issues. Robcat I'm very grateful for your guidance. There is a better than good chance that I'm the one with the problem here and the tutorial is just fine. Here is where I ran into problems.
1) One of the things Robcat said in the tutorial: "the path action is always setting itself to the length of the choreography and the choreography is always setting itself to the length of the last keyframe." Somehow I broke this. I've been having to manually increase the size of the newly added choreography and even have to manually increase the area not "grayed out" in the timecode at the top of the timeline view. I think it has something to do with number 2.
2) When I added a new choreography action like Robcat did in the tutorial it didn't appear as this nice short little bar like his did in the tutorial. It appeared as a huge long bar the entire length of the already existing animation. when I slid it over to measure up with the point in which I wanted the walk action to end and begin posing manually it increased the blue choreagraphy bar and available animation time by double. So every time I sampled the animation it would continue to play 20 seconds or so past the point where shaggy freezes and I'm trying to pose. This became frustrating for me so I shortened the blue bar and new choreography action (red bar) until the only time it took up was the area in which I was currently working. That didn't work because in the area at the top of the timeline view that "time" had already been exposed and was white instead of gray. I selected that area where the animation stopped (a good twenty seconds passed where I was working) and dragged it back to the time where I was working so when I played the animation it would stop in the area in which I was working. Ever since then I have had to manually adjust the choreography and timeline to add more time when I add more animation. If I do not the scrubber reaches the end of the time/choreography and just stops without playing the additional frames.
3) What was described in the tutorial with adding a new choreography action didn't work exactly as described in the tutorial. When I married up the new choreography action to the exact time that I wanted the old choreography action (with the walk action applied) to end all the new poses affected the walk action despite the new choreography action being in place and the old one ending. I discovered if I seperate them by one frame it worked as described in the tutorial. But I had so many other issues down the road (that bled back into the walk action despite the fact that at this point it was working and transitioned to the posed action just fine) that I cannot be sure this is not part of a bigger issue.
4) I watched Robcat's tutorials on key frames (both of them) several times and no matter what I tried it didn't help me here. I used the project workspace to control/select all the bones (that wasn't in the tutorial but it seemed to work); I tried control selecting the bones themselves; I tried nudging them to force keyframes, I tried shift/click on the keyframe button once I had the bones selected and I even tried edit/make keyframe with the bones selected. No matter what I tried there were certain elements of certain bones (most notably the hips, back, back 2 and ankle manipulation points) that had no keyframes and didn't even appear under the bone itself until after I manipulated it.
The project that I've zipped shows Shaggy walking up to the door and it transitions pretty seamlessly to him stopping, canting his head and then knocking on the door. He waits a bit and then cants his head again. That's where this project stops. Last night I moved forward. From there I had him sort of crane his neck to the right and lean back like he was trying to look around the edge of the door to see if anyone was coming. I then had him lean to the left in the same manner and then back to the center at which point I was going to have him grab the doorknob and start the lesson proper from there.
After struggling with these hidden areas of the bones that popped up (they would just appear after I manipulated them; they would say translate instead of transform and before I moved them they didn't even exist in the project workspace. Heck, back 2 doesn't even show up in the project workspace. So as soon as I move them they gain a keyframe that starts a movement waaaaay back at the beginning of the animation and slowly moves into place until the keyfram is reached. It usually ends with Shaggy canted over on his side knocking on the door sideways instead of standing straight up. And if I undo it so Shaggy is standing back up again and get rid of the keyframe, the bone disappears so I can't keframe it where it is, where I want it to be, before I make the cant to the right pose (with Shaggy standing straight in front of the door).
I played with the different areas of the shift/make keyframe menu. I even tried to force keyframes on everything just to try and solidify Shaggy's position where I wanted him. This resulted in Shaggy being turned around backwards and slammed into the door as if the two models had been merged into one. When I tried to undo it it turned everything white (complete loss of color and shading) and essentially did nothing else. Shaggy and the door became one and that was that.
So I tried to find ways to manipulate all those hidden bones and then put them back where I wanted them so they would have keyframes and although it took forever I thought I finally had it. As I scrubbed through Shaggy knocked on the door. Canted his head, leaned right, leaned left and then straightened up. It seemed like everything was working and I was ready to have Shaggy grab the doorknob and begin the lesson proper. Until I started the animation back at the beginning to watch it all over. As Shaggy neared the end of his walk cycle action his feet slowed at the very end and the last step took five times longer than its should until finally the scrubber passed into the area where the walk cycle ended and the posed animation took over at which point Shaggy snapped back into the proper movements and continued until he reached the end of the animation I had posed for him.
So essentially, I had broken down the animation into four parts. The walk to the door, the knock/check of the door, the pull on the door and the end walk through the door. I had all kinds of trouble transitioning from part one to part two but I got it. Then I had all kinds of trouble completing part two but I got it. The only problem was it ruined part one; and no matter what I tried I couldn't get part one to work right again.
So I came to the forums to write all this stuff and ask for help... but as you all know the forums were fubar last night. So I gave up. I didn't want to save the project as screwed as it was (and I was so wiped and frustrated I stupidly didn't think to save it as another file name) so I just shut it down without saving because I knew the last save point, what I have given you here in the zip file, was as close to working as I've been able to get this nightmare.
So there it is. HELP!
I've included the walk action in the zip file because I made it myself, therefore you probably don't have it. If you need anything else from me to analyze this problem please let me know. I'm basically stuck and don't know what to do to go on from here. I'm afraid if I invest tons of time in part two again I'll just ruin part one again. Thanks for reading this massive wall o' text and big thanks to anyone who can help.

I realize I'm asking for help with things that according to the lessons I don't need to know yet but despite that these are things that I intuitively feel I need to know, that I should know about how the program animates.