As it turns out I may have discovered the critical error with the HOD. I purchased another therm/hygro and put it at the bottom of the egg height. Turns out it's pretty cold there.
Now what is interesting is that I had 2 different thermometers in there already, one digital one mercury. One at top egg height, one at bottom egg ht. They were showing a fairly constant temp of 101F at the top, 100F at the bottom.
Well turns out when I put the new thermometer in there it was cold at the bottom!! About 97F!! This could explain all the hatcher problems.
So even though I had 2 thermometers in there, if they are both off... puh.
Both hygrometers are running about the same.