I've just been talking to Anna at Jetbrains, seems there -was- a build that updated its internal version to 6.4 which resolved the problem using 6.4. However, because the problem stems from a change in the protocol this then breaks using earlier versions of TestNG so the change was reverted.
The heart of the problem is that the IntelliJ plugin uses the internal testng version for its UI, but uses the projects testng version for actually running the tests ( this way you get consistent test behavior between maven/ant/idea builds, but it does mean a protocol change like 6.4 introduced can cause breakages ).
Anna mentioned she'll be working on a testng-independent protocol next week to solve the issue, there doesn't appear to be a Youtrack ticket for this yet but I'll keep monitoring the state of this problem and keep the list updated.
Mark
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"Great artists are extremely selfish and arrogant things" — Steven Wilson, Porcupine Tree