Distill off all the IPA, extract with water, increase pH, extract with DCM or xylene and gas this time Sounds like you had some weak crystallization going on. If your solution was dry you would have said, "my stirbar looks like the abominable snowman" but sea urchine implies that crystallization is not proceeding correctly, most likely due to water. Even over acidified and wet you can still extract with water and convert back to freebase. I offer chemistry consulting services on silkroad under name "ron paul"