I finally figured this out!!
It wasn’t the solenoid expander board. I put in another one from a different game with no change.
I finally got my new 0.05uf capacitors in and 1n4007 diodes. I started with the switches that had capacitors and replaced them with new. Then play tested.
The issue was still there; BUT I found some consistency. I noticed when targets were down on the 123 bank then the green targets started activating when other switches were hit. So, I looked closer. The problem was when #2 was down. Consistently, left pop bumper triggered 1st green drop, bottom pop triggered 2nd green target, and right pop triggered 3rd green target. None of this physically spotted/dropped a target, so when the 3rd green was triggered the ball in the captive hole would kick out to up targets.
Took my multimeter to the diode on that #2 drop switch; and sure enough; shorted. Replaced all those. Play tested. No change???
Tested again, still shorted. Removed the diode on #2 and tested that to see it was fine.
Turns out, way back when I was populating the underside of the playfield during the restore; that switch fell apart. I put it back together, but missed a spacer between two of the switch leads; so it acted like the diode was shorted.
I drew on the switch matrix to represent what was happening: With drop #2 down, that sent power down the red path. Then when a pop was hit on the green path; it would back-feed through and trigger a green target. This is likely why the problem was worse when the capacitors were installed on the pop switches.
Looks like everything is fully working now; so I'll call this one solved.
Now I just need to upgrade/modify those pesky linear flippers....
fathom switch matrix problem (resized).jpg