Have you taken the cover off of the ink pump to clean the conductivity sensor? Did you reload the ink files when you rebuilt? You could also set your optical density a bit higher when you colour calibrate - (this is not a long term solution, just a quick fix)
I run an Indigo 7800 and I was a litho minder until 6 years ago. We have litho too and quite often run make-ups on the indigo of jobs that come up short. I have not seen another digital press that can match litho so closely. I believe you need to be printing around 2 million clicks per month for...
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