what am I missing? 95% sounds like a very good signal strength. ...
I agree that 95% should be fine for virtually any signal, particularly with a Twinhan, which generally gives low quality readings. A 95% quality should give you virtually no "uncorrected" errors. There will always be errors, but with the FEC you shouldn't get many that aren't corrected.
I would think that it's more likely a problem in the computer side of the setup. For example, I know I've mentioned this before, but not sure if in the NOAAPORT threads, but I've found that my Twinhan conflicts with SATA hard drives. This becomes very evident if you run TSREADER, or any other program that shows any error/lock statistics. I would have a transponder locked, and giving zero uncorrected errors, then I would start a sizeable file transfer to or from my SATA drive (at the time I had about 3 internal hard drives, one of which was SATA). Any time that SATA drive was active, the Twinhan would basically stop reading data. The error numbers would start flying, and it would be trying to re-sync/re-lock, and I'd eventually lose lock completely if the data transfer took long enough. As soon as the data transfer was finished, it instantly went back to error free reception.
This was NOT a function of the CPU being over-taxed, it was a clear conflict with the SATA drive. If the transfer was between any other drives, I wouldn't see any errors.
Anyway, I'd recommend pulling the transponder up with TSREADER, and watch the error categories while you transfer some large (like a 2 GB video file) file between drives on your computer. I'll bet that some device or process on your computer is interferring with the Twinhan. This could be why the problems are related to how big the files are, in that when saving a big file, the hard disk process has a higher priority,... or, perhaps the computer itself isn't fast enough to process the data, and not enough processor time is devoted to the Twinhan.