Dave when using ContextRouter all you need is to create a few context settings, mainly:
- http_host
- site_start
- site_url
These are the most important ones, I recommend you also create context settings for:
- site_name
- error_page
- http_host_aliases
- base_url
In order to get ContextRouter working properly with your sites.
Once you do this you will see how much easier it is than the manual method you are trying to use right now which will cause a lot of issues with extras that are not coded to handle multiple contexts and have tons or url rewrite issues.
Also make sure you get rid of all the stuff you did manually otherwise it might cause issues with ContextRouter.
I hope that helps, good luck.