Well, I must have either screwed up in my assumptions or this filter is a little out of whack too. The numbers in the manuals match, even the VCO frequencies, so I assume the filters started out the same, but maybe it drifted a little.
I feel like an idiot calling the alignment done before zooming in and looking closer. After seeing the harmonic problem fixed and things on the SA looking good zoomed out, I took a quick look at the waveform using the scope as I put 200 to 2.5kHz into the mic. Why I didn't use the SA, no clue. Intensity didn't drop much at all. Sounded good on the air too, great reports, even called the guy on the other end to hear for myself. All seemed GREAT.
All was not great, he could hear me on the other sideband. Not as loud, but I was in there.. Checking with the SA, I now see that 1kHz into either sideband produces the desired signal, but also the same signal in the other sideband that is 20dB down. If I put 1kHz in, say on 27.205 USB, I get the 27.206, but also 27.204 at -20dB. Works the same the other way. The rolloff in the other band begins at about 200Hz and doesnt disappear until about 1.5kHz. 20dB is less than 4 s-units difference, thats not acceptable. My washington does not do that.