[Karl]

You should not run the mastering procedure after calibrating your robot.

I guess I misunderstood this note, this must refer to doing what you're saying - master-only parameters first, then enter them into robot, then full calibration. I did full calibration, remastered, then full calibration again, and got a worse result. Pretty sure at that point I also had the updated joint lengths in the machine.dat of the kuka though, and not in robodk.

去巴ck to defaults today and restarting. Only takes about 25 minutes now for base, tool, and 65 calibration points, I'm very happy with that!