TOPIC:

At a guess the suspended material just settled out to the bottom of the wort when it was left undisturbed.

I'm wondering did it settle onto element causing cutout? Would I have avoided cutout if I had boiled straight after mashout????

I'd say it didn't help.

I think you should fit a bypass switch to the thermal cutout on your boiler.

There are some pics here, and it'd be fairly simple to bypass that.
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I've been trying to avoid bypassing that Shane but a switch as you suggest might be a better option. I just don't like overriding a safety feature because I brew in the kitchen. I might just remove the thermostat from the boiler base a few mms so it'll react to extreme over temp, like a boil dry, but not cut out every time there's a buildup.

Ok, to be honest that sounds like a result to me. I'd suggest that you keep a stir on in future, don't let your wort settle post mash until it's at the cooling phase and I'd say your problem will be much minimised. I still don't think you'll eventually get around the need to bypass the cut out, but keep on keepin on <!-- s:) --><img src="{SMILIES_PATH}/icon_smile.gif" alt="" title="Smile" /><!-- s:) -->

I'm lazy too...what was the actual efficiency and is it much improved? I see the figures there but have no brew software on here to work it out.

<edit>Your iodine test is bang on by the way so conversion looks good, if you do some earlier ones or just test directly with some malt flour you'll see the difference, very pronounced, obvious black flecks.