Turns out the “issue” I found with the effects loop seems to be normal, I checked my Mark III and it does the same thing.
There is a small amount of hum / buzz, which I’m hypersensitive to, but when I fire up my Mark III the fan drowns it out, so I don’t think it’s any different from a normal Boogie.
Maybe it’s time to stick the fork in and call this good! I cranked it up today and was able to get really good sounds out of it, I think the only pot tapers that are off are the master volume because I had to use a 250k instead of 100k, and my lead master as I have 4-5x the LDR ground resistance compared to the real deal.