Quote:
Originally Posted by MattT516
Similarly, I had a situation with Lance Berkman in my 2011 Mets where he was hurt in mid-September, was playoff roster-eligible, and had no DL time left when the first round came around but couldn't put him on the playoff roster. After winning the NLDS, I had to figure out how to get him onto the roster in the NLCS. Here's what I did:
1) Get your active roster of 40 players (roster expansion) back to 24 men (if you can), and then add that injured player off the DL back onto the active roster.
2) Add him to the playoff roster.
This was the only thing that worked, as even though I only had 28/40 spots filled on the active roster it was reading as 25 slots available. Once I got it under 25, it let me add Berkman back on.
Hope this helps, because it was driving me nuts as well. I had to start Bryan Petersen and Fernando Martinez in an outfield slot on a playoff roster. 
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I am curious about one thing that I see many people do and you have too. Why DL someone when they are hurt in Sept? You can have the whole 40 man active so unless you 60 day someone because your 40 man was full and you really wanted to get another guy up there is no reason to, unless I'm missing something.
FWIW I never move a guy to the DL in Sept. as it is unnecessary and, whether pre v12 with no playoff roster or now in v12, will help avoid any issues that may come up. IE put guy on DL assuming he'll be off in time for playoffs only to find he's had a setback that keeps him out of games one and two and stuck on DL (can't activate him because he is injured). If he's left active, with injury, you can leave him on the roster hoping he is back in game three. Of course you run the risk of setback and playing one short for the series but that is the chance you take.