This may go against everything BW, but what if you stuck with a "routine" of eat activity sleep, but instead of starting with a specific A time, just watch his cues. Maybe he will surprise you and can do a much longer A time than you think. Maybe once you hit 1.5 hrs make sure to keep the activities not too overstimulating in case you need to get him down. I found that for S, at one point, I was trying to stick too much to a schedule than a routine. Once we figured out her A times by what SHE could do, not what she was "supposed" to do we were able to get on more of a set routine.
Also, what is your wind down look like? I found that a much longer wind down was needed around 3 months. We would (and still do) start just walking around the house or sitting looking at books the last 15-20 minutes before starting the actual routine. Then we'd do a diaper change, put on her sleep sack (swaddled still at that age for her), read a story and then sit in the dark with some lullabies for a few minutes. Then once she was relaxed, but not asleep in my arms, I'd lay her down to sleep.
Another thing, what does his A time look like? If he's lying/sitting with toys hanging over him most of the time he could be getting OS. That was another thing I found with S. She needed a variety of activities, but not all with toys hanging over her head or with just one toy, not 5 that are often on the play mats.
We also found that S could resettle herself even if she woke up smiling and chatting. Do you have a video monitor that you can watch him? If he's okay, maybe see if he goes back to sleep on his own after a few minutes.
As for the paci, I'm the wrong person to ask about that. S still uses one for her naps. We have the wubanubs, so she can replace it easily herself and could pretty early since it has the little animal on the end that helps her grab it.
Sleep usually does beget sleep. However, if he's sleeping more during the days only after a rough night, he's still playing catch up the next day, so he still may not be as well rested leading to another tough night.
Is he eating every say, 3 hours during the day, to make sure he's getting enough. I guess you had said he's not eating at night, so maybe that's not the issue.