I shortened the wiring run as much as I could between the batt-to-board and the board-to-output and am now getting 11.2 Watts max. So Ive increased the Watts a bit by shortening the run. Shortening the run also helped with the Watts fluctuation when repeatedly pressing the atty switch, more stable now. Now its fluctuating by 0.1 0.2 Watts when before it was fluctuating by as much as 0.5 Watts.
I soldered 20 gauge wires directly to the batt + and poles and bypassed the batt holder didnt change anything so the batt holder wasnt creating a problem. Brandon had suggested I make sure the batt holder is rated for 5 Amps and I wasn't sure what it was so it was good to know that the batt holder wasn't a prob.
I did measurements with and without the watts meter - there were no significant differences in Watts. The watts meter actually gave me a smudge of a better reading. Im also using an auxiliary battery source to operate the watts meter so it wont draw off the source batt.
Measurements were taken using one 18650 AW IMR 2000mAh batt and a 1K ohm trimmer.
Here's the data with/without the watts meter (only did max output as there's not a prob with min output):
1.5 ohm DCC: with watts meter = 11.2W, 2.65A, 4.24V ::: without = 10.8W, 2.55A, 4.24V
2.5 ohm DCC: with watts meter = 11.1W, 2.09A, 5.34V ::: without = 11W, 2.05A, 5.36V
Standard 3 ohm SCC: with watts meter = 11.1W, 1.92A, 5.76V ::: without = 11W, 1.91A, 5.75V
510 standard atty (2.4 ohm): with watts meter = 11.2W, 2.14A, 5.22V ::: max = 11W, 2.10A, 5.22V
I would have expected the watts meter to give lower results cuz the probes did add to the wiring run, but it didn't so can reliably use it to take measurements. Of course, the wiring gauge from the watts meter is HUGE - so maybe that helped too.
I am excited that I was able to get 11.2 Watts!! Now trying to figure out what next to do to get 12 Watts.
If anyone thinks of anything else I can try to get to 12 Watts, let me know.