did you try to remove those switches (e.g: -optimize)?

I don't know much about Q3 mapping but I remember reading stuffz about people were unable to generating aas files for complex maps, so they just made a simplified version of the map for the bots and attached that aas to the fully baked map with an external utility.

You could try with a simple box map (test_bigbox) to make sure that the problem is not with your map but with the conversion or the translation of the aas file.

ps.: again, I just remember reading about this but never made a Q3 map myself, so sorry if this is all wrong, just trying to help:)

I don't know much about Q3 mapping but I remember reading stuffz about people were unable to generating aas files for complex maps, so they just made a simplified version of the map for the bots and attached that aas to the fully baked map with an external utility.

I think you are refering to this:
http://www.simonoc.com/pages/design/maps_q3/pom_bots.htm
It's only needed for really complex maps.

yes, there was a SP map he posted here on ESR some time ago what I really liked, and I remember it was so awesome I googled his site and red everything there:)

Apparently the problem lies in changing the version of the bsp from Q3 to QL. This screws the link between the bsp and the aas files.

Thanks to cityy for point out that it is an unnecessary step, and apparently a harmful one.

I've been asking people on Q3W about this again:
http://quake3world.com/forum/viewtopic.php?f=10&t=47106
Just in case you are interested in some more info.