Can you measure the segment current ? For a given current, the brightness 
should be similar for tubes in the same condition. If not, there is a 
problem with manufacturing consistency. As VFDs age, they produce less 
luminous output. Some will develop visible dark bands nearest the 
filament(s), due to greater electron bombardment.

Mitch - You did a great job hiding your board where it's "really hacked 
up". Picture looks like a mature product that's been pulled off the 
assembly line.

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