So I accidentally did some more work on this last night (was planning to have a week off thinking about timings!)
In the light of the CT60 results I ran Doug's new program on DFB1 in release configuration (at 16MHz mode) just to get a feel.

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So broadly similar to the CT60 stats, but actually just a smidge slower on all but one of them. That's probably down to the edge I choose to sync to and perhaps recoverable in firmware.
But then I started playing with GALs again. And then firmware again. And then this happened:

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So this is with one GAL changed (to remove that extra delay in 'DMA' mode) and then a bit of a firmware tweaking. The firmware tweaking is light enough that it may be possible to set it from a register so a user could possibly opt for a GAL mod and fast DSP if it were important to them.
However, it's not perfect. I still can't pass the cartridge test:

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Which brings me back to the work I was doing on the cartridge and is perhaps the next direction for travel.
There is the additional consideration of what might break with the GAL mod, of course. How does DMA to the DSP work, for example? Is that thrown off? Can anyone suggest something that uses that so I may test it?
Additional good news is that Acetracker seems happy with the new DSP timings, however it will only work relaibly in 16MHz mode as in accelerated mode things seem to break down during screen mode changes (eg. it will start up fine, but when you click load and it reverts to the file selector in the normal GEM desktop, the screen will blank out). So that's probably clock switching related rather than DSP-influenced.
I also ran
@dml's 'normal' Badmood for DFB1 and that seems to be very happy. Buttery smooth, I may say. There's also a '56k' build in there, which doesn't work, but I forget what's that's for? Accelerated DSPs? Can't find reference to it in the readme.
I suppose I need to test Cubase Audio somehow now.
@exxos, did you get a test case in the end? I presume it'd have to be a hacked version.
BW