build steps
First boot with no lab supply anywhere: the real packs, through the real busbars, regulators and rails, running the real trays. Everything up to this point has been on a bench supply.
With the single thruster in water at low throttle, confirm it is mechanically and electrically healthy.
The thruster runs smoothly both ways with symmetric, sane current draw.
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The Pixhawk currently reports VECTORED_6DOF, which is the 8-thruster frame. The design has always been six thrusters (4 vectored horizontal + 2 vertical, spread fore and aft for pitch authority).
Set FRAME_CONFIG to Vectored (6 thrusters) before any motor test. Left on VECTORED_6DOF with six thrusters, the mixer commands outputs that do not exist and the vehicle fights itself - it will look like a thruster or wiring fault.
Verify in QGC that the motor test page shows six outputs, and that each one spins the thruster you expect in the direction you expect.