Hello John,
I think I've interpretted the dates of your Guidelogs. Being from the UK, I took the log dated 2021_07_09 to be the later one (i.e. 7th September 2021) .So, my suggestion of a greater Periodic Error in the replacement drive isn't the answer to your question. However, it is interesting that the hypertuned drive trace (2021_07_09) shows a larger periodic error at 484 seconds ( which I assume is the worm's cycle period) than the replacement.
The two graphs are analytical tools available within the Guidelog Viewer software, which you can download from the PHD2 website. This allows you to 'replay' your guiding sessions and examine various aspects of drive performance, including its periodic errors. Having read a bit more, it seems Hypertuning also includes reduction of periodic error, probably by a combination of the mechanical refinements you described and through periodic error correction using specialised software like PEMpro.
Hopefully, someone with a deeper insight will offer help.
Cheers,
- Jack