I don't think that PackBSP is manually packing my custom content. I tried manually entering it - I also tried using PakRat to manually enter the content - but neither seem to work.
Please consider downloading the manual version - a zipped-up version of the folder and custom content you can drop on here: C:\Program Files\Steam\steamapps\[username]\team fortress 2\tf.
This manual version is here:
http://www.megaupload.com/?d=KWNET6YD
Thanks.
(True, it's a bit more work...)