Well I tried the new firmware. It made things better with regard to roll/yaw coupling but brought on some new stuff. Now the roll axis finds horizontal much better but every so often it will suddenly move quickly by a few degrees for no apparent reason. Same with tilt it seems. When I hold the craft and gimbal in my hands and move it around in a mirror, stabilization is very good. Smooth and accurate. Once it gets in the air things change. My thought is the following things that could be causing these in-air issues:
1) Mechanical deficiencies in the gimbal. Like slop between moving parts or lack of rigidity.
2) Wind or turbulant air hitting the gimbal and causing vibration or "bouncing". This one ties in with 1).
3) Vibrations making their way down to the Hoverflygimbal.
4) EMI/RFI from the other electronics on the craft interfering with the hoverflygimbal.
1) & 2) The gimbal I have built is very rigid and I can percieve zero slop at the moving parts. To test this I turned the hoverflygimbal OFF and flew the craft around as fast as I could making rapid changes in direction over and over again. The video shows smooth footage. Of course its not stabilized but there is no bouncing or jittering or vibrating... This prooves my gimbal structure itself is rigid and "non-sloppy". So I don't think 1) or 2) are cauing the issue.
3) After I upgraded my firmware to 1.9 I fabricated a pretty nice additional antivibration plate to mount the Hoverflygimbal too. Plus if you look at my footage you can see zero vibrations in the footage. Part of this is because I am using avrotos and well balanced blades. Point being I don't believe vibration is casusing my issues.
4) I think this is causing the issue. Hopefully when my enclosure arrives it will resolve the issues.
Firmware 1.9 is out??? I'll try that and see if it fixes my issues.