Pin 2 = data out, pin 3 = data in. Is something missing from that answer? There is a possibility that it is wrong and that the two are switched, but that would show up immediately during testing.
It sounded to me like it should, but part of the task is to put the stuff together and test it. Anyway I think it is better to use a board with two uarts. I checked, and the Arduino Leonardo has two, so it sounds like that is a suitable board if you want to use the Arduino approach.
The USB software is present in the boards that have USB host ports.
Right, that is the purpose of those boards that I linked. To convert TTL levels to RS232 levels. You connect the UART to the level converter board. That is pretty much the same thing that you already did with the homemade MAX232(?) PCB, thus the idea of swapping in this other board and seeing if it works where your existing one doesn't.
I am glad to hear this. So what happens if I ship you boxes that I've tested on my bench and that supply the right voltages as shown on a scope, but only half of them work at the customer site, like with your boards? Who is responsible?
The Leonardo looks good to me but obviously I would want to test an evaluation unit before settling on it.
I would have to check that. However, disconnecting pin 2 or 3 can in a cable like that can be done with a wire cutter.
The suggestion further up is to use that level shifter card.
Yes, that's why nobody else wanted to do it either until you mentioned a figure of $300 per box. That is enough to cover the necessary amount of derping around that always afflicts a project like this. You've done a lot more hardware stuff than I have, so I shouldn't be the one who has to explain that.