Post-mortem
I`m glad to report that the amp has been running flawlessly for 3 days now and it`s sounding just fine, no snaps, crackles, pops or other mystery noises, running cool too despite the higher than normal bias.
I haven't yet had a chance to do any critical listening so I`ll have to reserve further judgement but do hope to prior to the Rev C install which should happen sometime next week.
This has been one hell of an experience with a good outcome. I haven't used or applied this much electronics practice since High School (late `70s) but always wanted to, I guess I got my chance.
I`m hoping some folks got something useful out of this thread as there is a lot of good information contained within, at the very least some entertainment. It ought be of help to someone in the future.
Looks like BIG problems have been solved, thanks again guys.