Hello.
Personally, I have never ran into a gap issue that wasn't related to non-whole numbers. The fix that always worked for me was to round the position/size to the nearest whole number on the stage. You mentioned that this didn't work, did you make sure that the stage coordinates are also a whole number, not just the local coordinates? In some projects, I even went to the extreme of rounding the position values by overriding/modifying the setX: and setY: methods.
If that is still no help, this might be of some use:
http://forum.sparrow-framework.org/topic/gaps-between-tiles#post-15280
There are many other topics on this forum regarding the same issue, but I can't seem to find any.