I finally managed to replicate my bug and record it as well.
I can make the following occur by using any channel.
If left at neutral there is no twitching, slight jitter but that can be put down to other causes.
1590 throttle 1498 alerion 1528 rudder 1558 elevator 1247 flight mode 990 flaps 1503 failsafe 1502 pan 1000 buzzer 1000 spare
1590 throttle 1498 alerion 1524 rudder 1562 elevator 1246 flight mode 990 flaps 1503 failsafe 1502 pan 1000 buzzer 1000 spare
1590 throttle 1498 alerion 1524 rudder 1563 elevator 1247 flight mode 990 flaps 1503 failsafe 1502 pan 1000 buzzer 1000 spare
1591 throttle 1498 alerion 1524 rudder 1562 elevator 1247 flight mode 991 flaps 1503 failsafe 1502 pan 1000 buzzer 1000 spare
382 throttle 1386 alerion 1499 rudder 1525 elevator 1562 flight mode 1247 flaps 990 failsafe 1503 pan 1000 buzzer 1000 spare
1590 throttle 1498 alerion 1524 rudder 1562 elevator 1247 flight mode 990 flaps 1503 failsafe 1502 pan 1000 buzzer 1000 spare
1590 throttle 1498 alerion 1524 rudder 1564 elevator 1246 flight mode 990 flaps 1503 failsafe 1502 pan 1000 buzzer 1000 spare
1590 throttle 1498 alerion 1524 rudder 1563 elevator 1247 flight mode 990 flaps 1503 failsafe 1502 pan 1000 buzzer 1000 spare
1590 throttle 1498 alerion 1524 rudder 1563 elevator 1246 flight mode 990 flaps 1503 failsafe 1502 pan 1000 buzzer 1000 spare
Note the single line of epic fail.
I was inputting a small amount of throttle then everything violently twitched.
I tried commenting out all of my code until all I was left with was the ppmin and servo out so I assed something up along the way.
When I did the testing the other day I was using 2 9g servos, in the test bed used here is 1 full sized sevro and an esc.
I'm going to double check my .h file settings and will post back if I discover anything I missed.
Code is available here if you need to look at it.
https://dl.dropbox.com/u/11371953/DIY_RTH_10.rar