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264p and/or 59.18Hz may be just enough out of spec that your HDMI hardware is rejecting the linedoubled output.
NTSC is typically 525 lines at 59.94 or 60Hz; 240p is usually 262 or 263 lines, making the line-doubled output 524 or 526 lines, which most displays will tolerate. So, 528 lines might be just one too many for your hardware to tolerate. Separately, or in combination with the line counts, the vertical refresh rate might be a little too low.
What line counts/refresh rates have you experienced with your other PCBs? Are they all pretty close to typical 240p or 480i at 59.94 or 60Hz, or are there some that work that are as off-spec as or worse than this PCB?