Wayne you are correct about the over modulation part, but I suspect that when testing various chassis the input was composite not RF. I can't think of any other reason why the manuals would state 100% saturated bars unless that were so, because it would lead to clipping of the top half of the signal. Not sure what that would look like on screen, but I suppose I can test and find out.
I haven't done anything to it but touch up some of the controls to make the bars as even as possible and even out the chroma and Y intensity, and already it makes great colors on my Trinitron without any parts replaced. I can see using the heck out of this thing, even if only as a demonstration piece.
Ignore the cyan bar bleeding over into the white, for some reason the camera picked it up but it's not nearly that bad in real life.