1. Proper tune up= [...]
That is basically what I did (peak grid, dip plate, increase load, dip plate). The fact that I get slightly more power out with the load all the way backed off makes me suspect your second suggestion below.
2. I know that you are running that thing off of a battery. First check and see what the input voltage to the powa supply is under load. [...] If your battery voltage is sagging under transmit [...]
Good point, I will check this.
3. How are you checking the outpoot?? [...] try tuning it into a good 50 ohm dummy load [...]
That's what I am checking it into.
The chain is like this: (tx)==>(mod scope tap)==>(power/swr meter)==>(dummy load)
(Now that I look at it I should probably put the the power/swr meter closest to the tx to get the most accurate reading, but I doubt it matters much. And is certainly of no consequence to this discussion.)
4 if all else fails give me a land line to discuss it furtha.
Will do. As always, thank you.