Believe me I'm always open to suggestions. As for using dark frame optimization I refer to
https://www.cloudynights.com/topic/801195-dark-scaling-with-latest-cmos-imx455imx571/ (which can be as clear as mud) which has some good points. I only restarted using darks with the 1600 as my 2600 is in the shop. I am curious about the use of Offset effect on Hot pixels. I just noticed that on some randomly chosen IC405 frames Hot pixels were 2-3 times higher for narrowband than wideband. For my 2600 the gain was 100 and the Offset 50. Maybe use a different Offset for the two bands? I am rerunning my full set of IC405 data in WBPP. I had CC threshold set at 3 sigma.
As for the recurring "focus" possible issue, maybe, but it still doesn't explain why I have no problem at all doing a full processing load of LRGB frames with any of my data in WBPP. Just narrowband (hence my S/N question).
I really do have many many Tb's of data taken over the last 6 months that exhibit the narrowband registration issue, which is why I resort to the kluge of running SA outside WBPP. Focus has not been an issue (for the 1600 a definite maybe). I do get that WBPP is basically a wrapper to run the processes, I just can't nail down the SA parameter differences in and out of WBPP.
BTW all this is really good stuff! I love this kind of analysis and I appreciate all the inputs!