Hi Mike, 

Stink, again no consolation, my system is running great (albeit with wired satellite) and in AP mode.

Have you tried posting on the orbi community forum? There are some keen members there happy to help

There was a lot of talk in the past about factory resets after firmware updates. I think you said you had, but maybe worth one last try.

If not, then a return might be the way to go....

One other thing you *could* try.....if you bridge your router and use the orbi as the main router, that might work better at maintaining the satellite?