Couple of comments: I have not left anything out of the process I use and while there might be something to add that could improve my bait a little, my bait fishes very well and doesnt need much improving. Keep in mind I use this process for all my eggs and only the rare batch sweats.
Spoonman, my eggs aren't burnt, burnt eggs are hard and crunchy, not soft and if anything wet. And what differnece would larger chunks make, if anything its harder for the cure to penetrate when the roe is in big pieces.
When curing, eggs first let go of their liquid, it mixes with the cure and then gets pulled back into the eggs. If your eggs are tracky/dry when you start then whatever liquid juices out, it mixes with the cure and gets sucked back in. Having too much liquid outside the eggs in the beginning will mean that when the cure mixes up, not all of it will be reabsorbed. I find that at the end of 48 hours, my eggs will have soaked up virtually all the liquid they originally gave up, everything has been reabsorbed including all the color from the cure.
I think its the drying process (ie rushing it) before I borax that somehow fails. Maybe there is nothing you can do and it is just the nature of the specific batch of eggs?
either way, I think i'll rinse this batch off in river water and recure them just ot see what happens.