Follow up:
I'm not ready to say I am past the problem, but have been experiencing my normal success.
At this point all signs seems to be that it was an encapsulation issue. It appears that spraying the inside of the screen with a lot more water than I did before and pushed the film into the screen with a little more pressure than before has resolved this. This would make sense as S mesh has more open area. It would also explain why this issue seemed to be more extreme on the lower mesh counts. I am not degreasing my screens. Which I never did before aside from the first time using brand new mesh.
I bought a new screen stretched with 150 S mesh (Thanks for the speedy shipping Spot Color) to test. I gave it a quick cleaning degreasing, rinsed it, coated it (no abrading, no water retainers), and it exposed and washed out perfectly. This leads me to believe it is not a new mesh prepping issue, film not dense enough issue, or exposure time issue. But more so an "extra water needs to be used with the thin thread mesh" issue.
If I find any other results/issues I will add to this thread. But otherwise we will consider this resolved.
A sincere thank you to all who took the time to give advice. A few of you really seemed to push me right into this direction from the get go. THANK YOU!
