the Power Dial and the CP500
I'm not familiar with the Power Dial. What is it?
By "CP500", do you mean the 500P probe that can be used for baseboard measurements? If so, it's a nice toy, but IMO not of all that much added value.
negatives with densities up to 1.00 in key highlight areas
So those are really very thin negatives? 1.0logD is quite thin for highlights.
The 500C pad lets you adjust the green filter intensity from 1 to 6
The 500 system works by altering the ratio between green and blue. It doesn't just adjust the green intensity. It adjusts both green and blue at the same time.
haven’t quite landed on consistent results yet
Please show what you've got and what kind of consistency problem you think you see.
The 500C pad lets you adjust the green filter intensity from 1 to 6,
Not sure which pad/controller you're referring to. The one I had allowed the grade to be set in half steps IIRC. I always found that perfectly adequate.
Or maybe swapped out the pad for one that allows finer control over filter increments?
Why would you need this? You mentioned split grade printing earlier. This gives you control over fractional grades that's virtually unlimited, even if your filters can only be set to the highest and the lowest contrast with nothing in-between.
I have a feeling you've started to dig a hole for yourself without really knowing why you'd want to do this, and you're now in the process of falling into that hole.
PS: I've used a 500 system for several years. I found it to be perfectly consistent and straightforward to use. I'm surprised you're running into trouble with it; it's literally as easy as setting the grade and the time and press the button. For split grade, you can set two (or even more) grade/time combinations if you want, although I never used that option much.