I've been planning a trip for some months now, SAN-LHR(Stop)-CPT, and am excited to have gotten ALL business with the exception of the final IAD-SAN leg on the return.

The only way you will get this in business is if you make changes as segments become available, biting the bullet on fees if necessary. Unfortunately this means you need to get somewhat neurotic about checking flights - even routings that might be somewhat absurd. My current routing is pretty good - through FRA on the way there and the "direct" flight JNB-(DKR)-IAD on the way back. I'm gonna keep looking for the JNB-JFK flight to avoid the technical stop in Dakar, but it is fine as it is if necessary.

Be sure to search everything segment by segment, of course. I used the Star Alliance site to make sure I wasn't missing any options.

After reading around I intentionally and actively avoided Egyptair. For some time I was routed through ADD on ET instead,even though I could have routed through CAI on MS. To me, ET's newer 787s, and the fact that MS is dry, made the difference between the two options. Lots of reports of old MS planes with domestic-style first seats. That was eventually replaced with LH through FRA when it came available.

I tried routing through Asia several times (at least 10 different attempts) but was never able to get an agent to ticket it. Most suggested it was a round the world, some said they could do it as multiple awards (though that complicates stopovers, open jaws), etc. I know some reports have suggested it is possible but I encountered no such luck, especially since I'm SAN based and the flight wouldn't be much different in terms of travel time. Keep in mind that if you CAN get an agent to book this - routing through Asia will encounter the Asia segment limits, which from my experience do not exist on awards to SA (My current reservation is 10 segments).