Geoff you are spot on regarding the tripod positioning. If you can set things up so the tripod goes back into the exact same place each time you setup then half the battle is over. Repeatability is key. I solved my problem by screwing three 5mm thick plastic discs to the concrete, where each disk has a hole in the centre for the tripod leg to sit in. Since doing this I rarely do polar alignments anymore, because I only do EAA with 30~45 second exposures. Of course when I do a PA, it is always really close so only needs a minor tweak.
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