To follow up,
it makes sense that the noise might be an issue, but it seems like version 5.3 creates the surfaces just fine regardless of the noise, so I'm wondering if perhaps there has been a chance in preprocessing before the end of the T1.mgz computation that solves the problem.
Would there happen to be any changes that were made to the normalization step that might be the reason why version 5.1 fails to create complete surfaces for these subjects while version 5.3 is working?
Thanks again for your help!