My iPhone won't sync, incorrect insufficient memory error

I have an iphone 4 32GB, running iOS 6.1.  I'm running iTunes 11.0.1 on my Macbook Pro.  I have a meagre 2.3GB free on my phone. 
In the last few days I have noticed that my iphone isn't always recognised: when I connect via USB I get the new phone set up screen - from time to time, but not always.  I became extra diligent about ejecting my iPhone from iTunes each time I unplugged it (I choose not to sync over Wi-Fi).  That seemed to sort that problem out. 
Today I'm unable to sync at all.  When I try, I get a message that my iPhone cannot be synced because there is insufficient memory; that I need an additional 18.3 GB to sync my library. 
I've restarted (phone and computer) and have even restored from backup.  I'm holding off doing a factory reset, my next step will be to remove and readd files to try and spot the problem. 
I think the problem is linked with podcasts: I have about a dozen that update weekly, and I have been keeping back copies on my phone.  All up my podcasts take up about 6GB.  I have nothing concrete to support my suspicion, other than that it seems that podcasts have been basically difficult to manage since updating to iOS 6.0. 
Any ideas?

Okay, I've deleted my backlog of podcasts, which freed up more than the 6GB I thought they were taking up.
I still had the same sync problem though.  I found an old reply to a similar issue on the forums, and the suggestion was to back up, delete all music, then reload it.  I'm in the process of doing that now - I've deleted the music, and am syncing to get it back on.  I'm currently at song 2667 of 3560, reporting 9.64GB free.  If I get to the end of this and get the same error message, I'm going to be mad!!!
What has become clear to me is that users have had this issue over several years now, and there's no formal Apple response, and (because it's still happening) no sign of a fix. 
It seems that the problem is that sometimes, when syncing, iTunes thinks it will be adding your iTunes library to your phone, in addition to the files already on your phone (i.e. it doesn't account for overwriting or skipping tracks already present). 
I'll keep people posted with my progress, and hopefully one day this will be useful to someone else in my situation. 

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