I'm happy to see that this technique is proving useful to some. I've never been so clever as this, and it feels great to have come up with something original that even seasoned pros find useful.
I did mention in my original post that the trick to getting this technique to work correctly is in getting the mask just right. And that means getting the stars to be the right size, and BINARIZING your values as Marc has stated. DefectMap only works with BINARIZED pixels. A pixel is either BAD (black, zero) or it is is not bad (anything other than zero).
Star masks can be tweaked using whatever techniques you like. I've used intensity transformations, convolution and morphology tricks to get my masks to work best. But remember, whatever processes you use, the last process should be a Binarize process.
If the problem with star removal is one of scale, you can always generate multiple masks at different scales and apply the DefectMap several times (I've done this).
Unfortunately, big stars cover a wide area and therefore a DefectMap fix will not be perfect. Therefore, I believe it is best to remove your stars in the linear state, when stars are as small as possible.
Last but not least, CloneStamp is always a last resort . . .