Maybe I found what's going wrong in the script/hack posted above!
Try using $bbuserinfo[...] where it says $userinfo[...].
At least that's the array used by vBulletin's original templates....
Another idea:
Would an external PHP-Script be OK for you?
You could link to that (external, non vB) page which asks for the username and then sends the activation request by itself.
That could be done quite easiely....
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