Check this out.
Scott Stapp - Live @ Fort Worth, TX - 03/13/2006 (Ridglea Theatre)
http://www.sendspace.com/file/fykgt1
When you sing in this condition, you cause damage. I know Scott probably didn't want to let the fans down, but years of this will result in nodes that eventually have to be operated on. This then helps so you can speak and sing in a limited range, but kills the range you once had.
If Scott was singing in this condition on the Armed forces tour and was smoking like a chimney, this could have resulted in flaring up his nodes or causing new calluses on the vocal chords.
Also, it is apparent with the amount Scott sweats and how much he smokes, he is dehydrated. This will make you horse right way at a sound check or prior and will not let you voice recover to its full range. Hydration, rest and stopping the smoking may help him recover his once very powerful voice. That is if he doesn’t already have damage from calluses, nodes or surgery to repair such ailments. Good luck Stapp! We want you back 100%, but most fans of yours will accept you for better or worse. Just let us know what is going on so we can write it off.