Koji came down to the dungeon to help me with the "what is the junk coming out of the PSL" problem.
We noticed that the beam right after the PBS looked funky, and the beam before the power amplifier stage inside the PSL looked fine.
We decided to realign the optics inside the PSL. We only touched the two steering mirrors immediately preceeding the power amplifier.
We got a 35% increase in power and the output mode looked cleaner to the eye. (No more solar flares)
We are now happy.
I will add pictures of what knobs we touched and how much each was turned by here