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I can't really tell you what happened specifically in the trial. I was not present. That being said, you can be charged with sexual assault without actually having sex. To forcible have intercourse with someone is rape, not sexual assault.
There are numerous offenses under the UMCJ that relate to sexual assault though, some requiring penetration but others that do not require it. So, the lack of them having sex or even having their clothes off does not preclude some offense has been committed. Sexual assault could occur by reaching under the clothing. Abusive sexual contact can occur without even touching the skin, but rather, making contact on the outside of the cloths.
It is not illegal to call someone and speak to them while recording them. This is called a "pretext call" and is legal when a warrant is issued.
The fact that she had a mental disorder does not legally mean she can't enter evidence.
Obviously, if he was convicted, the panel members must have believed her version of events and considered the statements he made against him. That's not illegal, so I'm not certain of what assistance you are seeking here. His recourse is to file an appeal through his defense attorney, but you've not mentioned any facts or circumstances that would warrant the result be overturned.
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