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1. Not much way to keep MF working with less overscan. You need to understand that MF is nothing more than a reset to the settings that you stored. If you can do DCAM alignment, you really don't need MF. Just let the set warm up a half hour before you adjust it and before you judge it.

2. You are likely not missing anything, other than you have not got the grid perfectly linear. The solution is to carefully measure or use an external grid. You may be getting near the limits of the adjustment that the set is capable of. Another method of reducing overscan that avoids these limits would be to shim the CRT bulkhead to move it closer to the mirror. This keeps you in the linear range of the adjustments.
 
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