We all have something to learn from each other. Keep this in mind, I'm not trying to say I know even a good smattering about chicken genetics. I know what I have experienced which includes keeping light brown leghorns, the blue egg laying brown leghorns developed by Bramwell at UARK, Silver Laced Wyandottes, Dominiques, Barred Rocks, Black Australorps, Sebrights, Ameraucanas, and a few other breeds over the years.
The only crosses that I have made and spent significant time studying the background genetics is the Silver Laced Wyandotte X blue egg laying Brown Leghorns. I made plenty of other crosses, but did not grow out hundreds of offspring to see the segregating genes. I have grown out about a thousand chicks from the SLW X BEBL cross and am growing another 300 or so this year.
Here are descriptions of the phenotypes of birds that I saw segregate out:
1. There was one hen that was yellow with speckles. I know the mother of that hen and am certain the yellow color originated from the brown leghorn grandparent. I only saw the one single hen with this coloring.
2. There were several birds that had orange/brown feather color. This is very different from the normal brown color of Brown Leghorns. The best way I can describe it is to look at a really well colored brown leghorn rooster at the neck and hackle area where they often have orange feathers.
3. Mahogany red is hiding behind the brown feathers. If it shows up, it is usually on roosters on or around the wings. Look at some of your roosters and see if they show evidence of carrying mahogany. This picture has a rooster with red wings that segregated from the cross.
http://www.selectedplants.com/miscan/2018chickens10.jpg
4. Penciling/partridge is carried by Brown Leghorns. It is mostly hidden behind the brown coloring, but if you look closely at the feathers on the chest and near the tail you can see the speckling effect. Look closely at the rump and tail feathers on these hens to see the effect of penciling.
http://www.selectedplants.com/miscan/slw.blue1.jpg
5. Puff feathers near the tail are common in Brown Leghorn. I don't want them on my birds. These are small puffy feathers just in front of the main tail feathers. This is caused by a recessive based on the crosses I made.
6. Weak chick legs showed up in Brown Leghorns This can be made worse by too high temperature in an incubator. Most of what I got was curled toes and sometimes legs that would not support a chick. I have not seen a case of curled toes in the last 3 years so must have gotten this gene pretty well suppressed.
7. I had one rumpless hen in 2018. Since rumpless is sometimes a hidden recessive in blue egg layers, it is likely this was brought in from the blue egg laying brown leghorns. This is not likely to be in a normal strain of brown leghorns.
No, they don't have to pop up. If a dominant gene is homozygous in a breed and covers a recessive, the recessive literally never shows up until a cross is made to a breed that does not have that dominant gene. Consider dominant white. You have certainly seen what happens when dominant white is crossed to just about any other breed. What do you get in the F2?