Hi John,
First of all I'd like to take a look at those images where SA is failing to build a mosaic. That would help me diagnose what happens.
DynamicAlignment can indeed be used to build mosaics. Being a semi-manual tool, it allows you to align images subject to arbitrary distortions without any limits, something that SA can't do. However, DA is somewhat outdated. A complete rewrite of this tool is scheduled after Summer. Among other things, the new DA tool will be able to generate mosaics very easily.
In the meanwhile, to build mosaics with DA you have to do some extra manual work. Basically, you need to generate a sufficiently large canvas with enough room to place all mosaic panels. This is very easy to do with the Crop tool (Geometry category).
First you have to guess the approximate final dimensions of your mosaic in pixels; let's call them W and H. Select one of the panels as your first reference image. Open the Crop tool and activate Track View. Then enter W and H as the target dimensions in pixels. With the margins/anchors controls you can define where the extra space will be added. For example, if your reference image is the top left mosaic panel (a reasonable option), then your margins should be: top=0, left=0, bottom=H-h, right=W-w, where h and w are the current height and width of your reference frame. Note that the differences H-h and W-w will be calculated automatically by the Crop tool.
Leave the fill color parameters with default values (to fill the extra space with a solid black color) and apply Crop to your reference image. Now you can register all mosaic panels over this reference image. The final result will be a set of registered images, each of them put in place over a black canvas. Now you can merge these images with PixelMath using the maximum operator. For example, if you have 6 mosaic panels P1 ... P6 then this PixelMath expression would do the job:
max( P1, P2, P3, P4, P5, P6 )
That said, I am very interested in knowing why StarAlignment cannot generate your mosaic. Could you upload the images somewhere?