Well I've finally booked my OWA for this Aug-Dec after nearly 8 months of research and planning. Wifey and I are doing the following in Y:
MEL-SYD-xSIN-LHR (QF)
LHR-BCN (surface sector around Europe)
BCN-MAD-JFK (IB)
JFK-YYZ (AA)
YYZ-YYC, YYC-YVR (WS - not on OWA)
YVR-SFO (surface sector down the US west coast)
SFO-DFW-SCL (AA)
SCL-PNT, PNT-SCL (LA - not on OWA)
SCL-SYD-MEL (QF)
Ended up only costing $1500 total in taxes and surcharges which I think was a good outcome. We avoided BA for the Europe-USA leg which would have added a couple of hundred $. We tried to get the Patagonia leg on the OWA with LATAM but A) PNT doesn't exist in the QF booking system and B) when I called the QF service centre they couldn't see any award availability on those flights. Also wanted the SCL-MEL direct flight with LATAM but they're not releasing award seats during Dec-Jan, so we're stuck with QF home via SYD. At least we can use the lounges as I'm Gold FF.