Ok, status report. As I mentioned, doing a factory reset on the Mesh Node by itself did nothing. Overnight I did the Mesh Router too. As suggested I did a full factory reset and rebuilt it from the ground up. I changed the absolute minimum number of settings away from their defaults, except Airrime Fairness is off. I left Roaming Assistant on. Both router and node are still on 32738.
After rebuilding the router, I had to do an additional reset on the node (not factory reset) before the router recognized it as a node and added it back in.
It's been up since 5am (6 hours so far) under load testing and so far it's been flawless. It also seems to be acting more predictably, with less weird stuff happening. Clients initially pick the strongest box and stay there (I'm not testing roaming) instead of unpredictably flipping back and forth for no apparent reason.
Before the resets and rebuilds I'm confident that I would have already seen symptoms by this point in testing, but it's cooking right along.
It took me about 5 hours to do the rebuild so I'm a bit sleep deprived, but encouraged.
Bruce.
Good work!
A few thoughts...
Until AiMesh firmware upgrades become simple fixes instead of AiMesh development additions, resetting all after an upgrade is recommended, imo. Likewise, it helps to keep the router configuration to a minimum for now to simplify reconfiguration.
Resetting the node before adding it to the AiMesh is required. I'm not sure I appreciate your distinction "
I had to do an additional reset on the node (not factory reset)". Either a button reset or GUI reset or GUI Initialize (clears logs) should do it, all factory resets... I prefer the GUI Initialize followed by a button reset for good measure... maybe even throw in a power cycle, too. Whatever it takes to preclude unnecessary distractions from the real AiMesh defects.
Finally, recent news here from ASUS suggests Smart Connect node band steering has still not (and may not) be added to the 68U (and related builds like your 66Us?). IMO, AiMesh without node band steering is not very worthwhile except for the centralized management and improved wireless backhaul rates. Me, I would not live with it... I sold my 2xRT-AC68Us and got 2xRT-AC86Us (on sale plus rebate).
Without Smart Connect, wireless clients may not connect to the desired band. As I see it, the only recourse for this is to define separate SSIDs, such as OE-24 and OE-50, and configure your clients to connect to the desired band. This may be preferable for some users with specific wireless clients like IoT clients.
Now, I wonder how your node will perform when you connect a wireless PC to it and run
http://www.speedtest.net/ or
https://www.dslreports.com/speedtest? repeatedly (until it slows down or completely stops?)...
OE