I want to thank all of the people who responded to my earlier posts and private messages for helping me out by sharing what they do and their thoughts I want to especially thank Greg Davis for the specific tip that he was never able to get Kodak Flexicolor SM within the process control limits in his rotary processor. Today I mixed up a 2L bottle of tank solution using Kodak Flexicolor LORR LU developer based on the numbers in Kodak Tech Pub CIS 49 "Preparing Smaller-Than-Package-Size
Amounts of KODAK Processing Chemicals". This morning I processed two Kodak C-41 control strips and 135 roll of Portra 160 for 3:15 in the Photo Therm Sidekick. (One strip on the end reels in the 4 reel drum of the sidekick.) I stuck with the ready made SM tank bleach and tank fixer which are mighty convenient. I measured the two control strips (and remeasured the reference strip for good measure) on an X-Rite 810 I had previously calibrated last month using a fresh X-rite transmission standard.

The results with the LORR LU developer are DRAMATICALLY better than "off the charts" results I was getting with the Flexicolor SM developer. (Despite trying changing the process temperature, extending the process time, and not doing the pre-wash in previous trials with the Flexicolor SM developer.) If I had to guess I would guess that the process of heating the chemicals in the broad hot-plate, pumping up into the drum, and the agitation all cause too much aerial-oxidation of SM developer, and that somehow the LORR LU developer is more robust. Not sure why the SM developer is so different.

Both strips are within the control limits AND the action limits. Averaging the two strips I get:

Values-Aims:
Dmax-Yb = 0.01
HD-LD (R,G, B) = -0.01, 0.05, 0.02
Color Balance = 0.06
LD (R, G, B) = -0.04, -0.07, -0.06
Dmin (R, G, B) = -0.02, -0.03, -0.04

Thanks again particularly to Greg Davis, Photo Engineer, and EdSawyer and others for your helpful correspondence.

-Justin