spike5150,
It seems like you have a good understanding of how this hli is supposed to work and are aware that things are out of wack somewhere that shouldn't be. I would advise that if you can take your heli and your calipers, or whatever you are taking these little measurements with, down to your lhs. See if they will allow you to mess around with a brand new untainted bcpp. Start piece by piece from the servos up and measure and compare part sizes and linkage range of motion until you find your trouble maker. I see you have a swash upgrade. possibly you obtained one that is a little off on the specs. Cheap plastic crap is also not the best material for producing thousands and thousands of little parts at a high level of acuracy. One part in your head that is a little long or short....sorry im rambling.....My point is- When troubleshooting there is no better method than having a control subject to compare your troubled heli to. Find another properly functioning bcpp. Start with the range of motion and response characteristics of the servos and when you are sure the 2 helis radio and electronics act the same move on up in order piece by piece through the head. From the servo arms, to the servo/swash links, to the swash....ect. and compare and contrast each part along the way and you will find something different between the two heli's.

Good luck, Noah