Yep, I found it - the "unclipped" check box which excludes 0 and 1. I also found the disconnect between our numbers - you were looking at stats for the Oiii frame (38.7% zero) while I was looking at the stats for the Sii frame (4.8% zero).
I looked again at calibration - the Output Pedestal field. The mouseover popup seems to indicate that this is applied after calibration (so post flatting). So I ran a series of re-calibrations of the Sii frame with pedestals from 10 to 100 in increments of 10. A pedestal of around 50 seemed to do well with eliminating the visible signs of the cross hatching. There was also no apparent impact on the flatting of the image so the pedestal does appear to be added after flatting the image. Curiously the images with pedestals of 10 and 80 showed mis-alignment errors - the 10 with visible signs of cross hatch and the 80 without any visible signs. This would seem to indicate that the presence of the cross hatch and the mis-alignment are not linked.
I looked at all of the alignment interpolation algorithms using the Sii frame (without adding a pedestal in calibration) with all values except the interpolation set to defaults (did a reset of the process). Some of them showed a visible cross hatch and some did not. The interesting things is NONE of them showed a mis-alignment. So it would seem that something in the other star alignment parameters that I had changed was resulting in the mis-alignment issue when aligning a frame with a clipped background. The lanczos-3, lanczos-4, and lanczos-5 interpolations where showing the most visible cross hatching, but much more subtle than using my normal alignment process (lanczos-5 with as yet to be researched parameter changes). The others showed no visible cross hatching. Interestingly the BiCubic B-Spline and Cubic B-Spline showed increased contrast over the other interpolations.
So it would seem, at this point, that adding a pedestal of 50 in the output from calibration addresses the cross hatch (at least for the Sii frame). Without the pedestal, 4.8% of the pixels are clipped. Adding the pedestal of 50 leaves only 0.0045% of the pixels clipped. At a pedestal of 40 (with slight cross hatch showing), there were 0.0064% clipped. Sounds like a target of no more than say 0.005% clipped would keep the cross hatch mostly under control. I'll need to establish what it takes with the Oiii frame to control the cross hatch since this frame has a weaker background than the Sii frame.
Since there are still clipped pixels after adding the pedestal, it would seem that the calibration process applies the pedestal and then clips the remaining negative values to 0.
This just leaves, I believe, figuring out the cause of the mis-alignment. I need to examine my alignment process settings versus the defaults and run some tests to see which changes are resulting in mis-alignment with a weak background.
Paul