Ah, I see what is happening here. At start up, something is actually removing the app file! And it is happening at start up, not later when boinc requests work from the project. WTF? Why would BOINC delete a file like that?

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Also, this message is further up (earlier) in the start up:

Fri Jan 6 11:53:41 2012 | Radioactive@Home | [error] State file error: missing application file usblib-0.1.4.dylib

I see that the actual file name included in the zip package is:

libusb-0.1.4.dylib

So I updated the app_info.xml to match the file name in a couple of places. Now the message says:

Fri Jan 6 12:06:14 2012 | Radioactive@Home | [error] State file error: missing application file libusb-0.1.4.dylib