Ben, randomly getting double kick outs and / or ball save immediately, so 2 balls in play - this is like the early bug way back when - haven't pinned down exact situations, but happens about every three games .

You are nearly there. The a/v is the main step in creating/installing on the SD card. A quick format is fine. seeing you now have AV version 23, means your Sd format and files creation was ok. Last steps - use the pinheck tool to update the code version to 23, which requires the cable to the port on the board. Follow the remaining steps on benheck.com/amh

Spandoi - beat you by 4 seconds

Set kickout coil to 4 (was defaulted back to 8),double ball or false ball save hasn't happened since.
Also had ball go under apron a few times before, seems to have solved that too.

I'd say switches. Orb, hellevator and the up/down elevator switches are relatively close to each other. I'd look for a wire caught in or near the leaf switches. I had false hellevator hits b/c the diode came lose on the switch at the exit of the Hellevator.

Switch test matrix helped me pinpoint it.

This. The SD card does the A/V files. The pinheck tool updates the v22 to v23 directly with the mini USB cable.

At start 3 bank is down, lock a ball at Ghost and 3 bank raises. Hit each 3 bank target separately to turn each flashing triangle insert from flashing to solid. Bank drops, hit back to Ghost for jackpots.