dc42 - That helped.
I did some more research and it looks like the SparkFun Serial LCD 2x16 has some reset issues: Serial LCD - SparkFun Electronics Forum
I've been using the latest SoftSerial, but when powering up the device with other power sources connected it just refused to display.
The key was when I noticed that it didn't even show the splash screen. <- this is how I knew it was the module and not my software.
I opened the box up and changed where the ground was. I was originally pulling ground from where the buttons and input ground was. Changing this to the board and making sure that was ground was connected to all of these sources together (board, LCD, buttons, input pins) seemed to make it start up correctly after resetting 80% more of the time. There is STILL something up with this LCD and I read that powering it separately or switching it ON after the Arduino was powered seemed to be the only way to get it to 100%.
http://www.flickr.com/photos/planetkris/8106241868/
Second issue - Free Memory
I went back to a working sketch that had no smoothing arrays. My weird string issues went away, and I had suspected that in the past.
I originally checked it with a function until I noticed this: Arduino Playground - AvailableMemory
"Note: For Arduino 1.0, you have to replace #include <WProgram.h> with #include <Arduino.h>." No wonder I never saw the values change 
Now I have 211 bytes free with filling 4 values into a smoothing arrays on all 11 sensors: aX, aY, aZ, temp, 1-7
When I change to only 2 values going into the array I have 233 bytes free... This doesn't shrink as I collect data for a second and flush write it to the SD.
When I fill the arrays with 10 pieces of data the program fails after logging for a few seconds. It doesn't even write to the SD.
Is 200 bytes of free RAM just not enough?
Guess I'll have to not smooth the data on the device - or go through a 3rd round of slimming my program down.
- Kris