Rick - sounds like you think it is a mechanical issue? I've had the dial gauge on the focuser and stepped it in and out and get very reproducible results.
I suspect it is the HFR calculation or variation in HFR due to SNR, guiding error or something else. I've seen reference to flat v-curves from fast optical systems in the Focusmax manual. I also notice the Focusmax V-curves recommend 30-40 points and aim to get a large variation in HFR over the curve.
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