You guys are barking up the wrong tree. Both Dr. Rob and I have suggested the issue is with the lever as that is what separates the hard and soft seats. If you want to experiment, change one thing at a time in the same regulator under the same conditions.
For the record: I still believe the manuals that state for maximum flow the vane crescent should face the aspirator is incorrect. Look at the wording: "facing forward toward the back of the diaphragm" & "facing forward toward the mouthpiece." What sort of double-speak is that? Someone just made a typo or editing error and (just like in the aircraft manuals I've read over the years) the mistake was copied by the script writer.
Speaking of aircraft, if I were to ask you to design an airfoil with a crescent; would you put the crescent on the leading edge or trailing edge?