What temp did you maintain to cook the rock? Learning not questioning. I have read about this process in the past but have not done it myself personally.i have always just replaced the rock in sections tell the aqua scape is fully replaced. Of course this also created mini cycles but when done gave us a fresh new look ! Old rock syndrome (I have no better name for it) is something to be considered for sure. I just think it is hard to determin if and when the rock has been saturated. I did this only when I was at the point of total loss of solutions. Tom you say you know that you have Po4 even tho your tests show zero. I think getting a new test is a good idea then see if the results are the same. Have you considered a bacterial problem maybe also. I know sometimes well water even water that has been ran thru a RO DI sometimes can create issues. Indications of small bubbles stuck to rock would be a sighn. Food for thought is all.