Have you tried a Cho-pat strap or similar strap, or some other patella
stabilizer?  I wear a Cho-pat strap, or one similar with an air pillow
instead of the tubing in front, whenever I'm going to be walking on
uneven ground, and I feel like I get nearly as much support from the
strap as some of the big sweaty neoprene braces I've tried.

You can see photos at
http://www.kneesupport.com/straps/index.htm

Last time I needed a replacement a couple of years ago, in a gap
between insurance coverages, a Cho-pat was about $12 (ordered through a
local chiropractor), so that site might not be a good place to buy one.
Your physical therapist can probably get you one, charged to your
insurance.

Sorry - I went awol for the long weekend.   :)

I'm still having knee problems.    It comes and goes.    I find that a
few days of inactivity is the best healing practices.   But one day of
the dog dashing in front of me and I'll twing my knee and it will hurt
for a few days.

The 6 weeks of PT didn't do a whole heck of a lot for the pain.  (and
you know - its not like you are going to see a great deal of muscle
"growth" or strength growth in 6 weeks by using 3lbs weights on your
legs).    Although the continued exercises over time and the return to
weight lifting but with caution has helped in the long run.

I did pick up just a simple brace - the elastic w/ the petalla whole
and reinforced side braces.   That helps alot, although fit and
comfort are not its strong points.

DH had me try his knee thingy - the one that jamie posted about -
Didn't help one bit for me.

I need to make a followup appointment with my doc to take this to the
next level - just have been putting it off.   The one thing that
worries me is the trip I have planned this fall to go visit Determined
and go hiking around Mt. Rainer for a weekend.   I'm afraid the hills
will wear on the knee.