I have read through all the posts. I still have yet to find a major flaw in our current state tournament set up. The most common thing mentioned was eliminating subs. Then move forward with eliminating subs. After eliminating sub-district move state up a week if you want or leave it.
We have over 10,000 card holders, counting coaches and competitors, and we have 15 posters on this stream. I don't think that is a fair representation of the populous.

If you eliminate subs for 6, 8, 10 then be prepared for lots of 32 man brackets. That means lots of matches and a long day.