Everything you've mentioned I'm sure I've done except to do the ef flash from LibrePilot. Trying to flash the ef from the all_fw1509 zip but it's corrupt. Is there anywhere to download the ef file for the Revolution?
You started by saying "was working .... with several hundred flights using a
Next release".
That means you have actually compiled
next branch of LibrePilot yourself. Since GCS must match firmware, that is to talk the same UAV objects as firmware does, it is normally compiled with GCS and is located in path
librepilot.git/build/firmware/ef_revolution/ef_revolution.bin
Then you provide path for dfu-util and using SBL flash it
dfu-util -d 0483:df11 -c 1 -i 0 -a 0 -D librepilot.git/build/firmware/ef_revolution/ef_revolution.bin -s 0x08000000
This assures your firmware (fw) and bootloader (bf) are matching together and correct. This step may not help with your particular problem, it is just to ensure you have the correct bootloader and firmware that should work under normal circumstances, when everything else is right.
To actually fix potential corruption in SPI flash, you need to flash with GCS resurrect image for Revo, but to be even able to do that, you must be sure you have the right bootloader that will boot it, hence step above is a way of ensuring it.
Hope it helps...