I am glad to hear reports of the original performance being satisfactory in this regard. Unfortunately the switch and interconnect choices employed do not stand the test of time, the modifications done have turned this console into a reliable and useable one from on that was completely un-useable because of constant noise and signal interruption.
This particular console was designed to work specifically with a Studer A-80, and MTR signal flow, monitoring and metering has very little to no use for modern recording and production techniques (specific to the demands of the owner). The entire reed relay matrix deals with the monitoring and metering via the "jukebox" and has no bearing on the 16 buss mix.
Properly wiring the outputs of the 1272 mix amps direct to patch has no bearing on the issue, it only lowered noise and increased reliability.
Yes, the technical ground scheme using the aluminum frame to connect the copper ground buss bar to the ground lug is not optimal, but this is easily cured. Yes, the "tie every shield to ground" scheme is not optimal (and cost them a small fortune that could have been easily saved) but this can be dealt with by proper termination of connections to the console.
One only need look at an SSL to see how grounding, shielding and termination can be implemented in a robust and cleanly functional manor.
Absolutely nothing has been changed in the implementation of the mix busses from the output of the routing modules to the 1272 buss amp inputs.
I am confident that Ian is correct in the source impedance being the root of the issue, and the mods to the routing modules relating to this.
The routing modules were modified to remove the quad / stereo / mono switching (which cut in and out with a breath on it), pans, and by doubling the poles used on the switch banks.
Now the switching and operation is quiet and reliable, but the load presented by the pan pot is no longer on the output of the 208 op amp on it way to the routing switches.
So the real question is, is 5K the ultimate resistance to put there?