Not having the foreign address in screen 1 was the problem.  One guy had changed it so his mom in the US would be able to get any notices, the other guy is where by the time we file the return, he will be back home in the US and had his US address in.  Just the luck of the draw that these last 2 guys were my only ones with US addresses on screen 1.  Funny, I thought just the attestation that you are out of the US on 4/15 checked would have qualified you for the extended extension filing date but apparently you must still be out of the US at the time of filing the extension.

Thanks for your help!