Live certificate creation fails but --test-cert works perfectly!

That's correct - it's the same validations.

I don't believe this is the case. I think that you had a pre-existing valid authorization for the domain in the staging environment that was reused. See this thread for more information.

If you want to test this theory, create a brand new account and try the request with staging and production. I expect that if the misconfiguration that prevents prod issuance from working is still present then both environments will fail using a new account that has no preexisting valid authorizations.

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