First of all, do not necropost (posting in topics that have not had a post in a long time), especially with your own issue, not an attempt to help the OP. I've moved your post into its own thread.
I need help with a QT ver. 4.8.5 wallet.dat that is corrupt somehow.
Bitcoin Core is not called Qt, and the Qt version is completely irrelevant. What is the version of Bitcoin Core (which is not Qt).
#1 trying to replace the wallet.bat file into the same dir but keeps failing and just hang
at "Loading block index" then no more.
How do you know that it is hanging? Sometimes Bitcoin Core can take a long time to start up, but that does not mean that it is hanging.
#3 remove all files except all the dll's and the config file
and restart, starts fine but all frome day 1. (sync and no Bal)
Of course there won't be a balance, the blockchain isn't synced yet.
#5 replace wallet.dat while wallet running... a program error pops up
and locksup the wallet completely.
Don't do that, you'll end up corrupting things further. You cannot just remove and replace files while they are still in use by the software.
Please post the contents of your debug.log file.