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Well, sadly once you record a session with a calibration, you can not just re-calibrate and have it work again once the cameras have been moved, so until you get a consistent process of calibrating before you record any final performances, you just have to write those others off as tests.
I personally also use a very rigid fixed camera mount to the walls, so really my cameras never move now, but that isn't necessary, tripods will work, you just have to be more careful around them, as even the slightest bump will change the cams calibration, why it is best to do 2 cals, one before and one after, always.
My calibration consistently is .11 - .15% misdetects and a reprojection of less than 1, (usually less than .65 on all cameras), so if it falls off that on any calibration attempt, I know something didn't go optimally and I re-do the calibration, but that is rare now.
Very bright room lighting will affect the calibration, even when extra darkening mode is used, best to have mild ambient lighting while calibrating and use darkening mode, do not turn off all lights though, it won't be accurate in my experience.
With an accurate calibration, the actor should match the performer very closely, and should basically for the most part remain overlaid throughout the performance, but the closer you get to one camera you move farther away from others, so a slight height appearance will occur, but it's not to worry about, it is normal and shouldn't affect the tracking.
What is your capture volume by the way? X m by X m or (ft x ft)
As far as the flexible spine, you should never use stiff spine, unless you need no spine action, and it will also throw off the tracking for a smooth human animation.
I use the very flex spine for the most part, and in some areas I switch back to flexible when the action is too extreme and it throws the hips too far forward especially on extreme dance moves with bending at the hips and the body rolling back up to vertical, you will just have to get the feel for how to use the different settings and when.
I can only speak from my experiences and it probably took me the better part of 3 months to be able to get the process to work as I wanted, because I use hired dancers and I can't have failed takes to just have re-takes at a later date, so a lot of trial and error and camera re-positioning was needed, but I think I have it working as good as it will now and I don't have to really limit the performers actions, except to not hide hands or feet from the cameras and always keep about a 6 inch perimeter off any body part when possible, (body, legs, head), the tracking works better and just easier to work with the animation in post that way.
I feel I get fairly life-like animations, with very little clean up, so I am happy with my outcomes.
The program with 6 PS Eyes works well, so it's just working through the calibration, which is the most important process, other than using tighter style clothing in darker saturated colors works best, and darker color gloves helps too.
Really you should not have to do very much, the program is pretty automated, except for the actor parameter choices and if you do use jitter removal, don't set any body part above "1", except the head only, you may want to add more to stabilize it better.
When calibrated correctly, your actor height should match your performer height closely, so to me it sounds like the calibrations cam off floor height for cam 1 is off, for the rest of the cams let the program set the height and position, even if not exactly the actual heights, within reason of course, (+/- 1 to 5 cm is fine), as they are just numbers estimated by the program, but the actor in studio should remain the appropriate height and positioning in all cameras throughout tracking.
Good Luck!
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