A little more in the way of updates… I started doing more code-debug, and found that when I dumped the query at line 256 of search.php:
if (is_array($meta_query)) {
$meta_query_restrictions = "";
$mq_vars = array('meta_query' => $meta_query );
$mq = new WP_Meta_Query();
$mq->parse_query_vars( $mq_vars );
$meta_sql = $mq->get_sql('post', 'relevanssi', 'doc');
$meta_join = "";
$meta_where = "";
if ($meta_sql) {
$meta_join = $meta_sql['join'];
$meta_where = $meta_sql['where'];
}
// $query_restrictions .= $meta_where;
}
the query had
...AND ( ( wp_postmeta.meta_key = 'vehicle_make' AND CAST(wp_postmeta.meta_value AS CHAR) = '' )
That would absolutely cause the search to show no results. Why would it be adding in the meta_key requirement here?