Secondary should be an exception rather than the rule.
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My understanding may not be correct. I don't see anything reliable to point too with a quick Google search.My understanding is that IBU estimates are for the fresh wort so its not surprising that the IBUs is the finished beer are substantially less.That is not my understanding. Can you point me to any reference to that? I am willing to read and learn.
My own experience was that Tinseth is the most accurate on beer samples.
Yeast selection can have a big influence. My samples used ones that were close.
Iodine tests are basic chemistry and very reliable. If your mash is well mixed and there is starch, the iodine turns black. That said I don't use them.
Too many adjuncts for the diastatic power of the Vienna. Vienna is only 50°L and most sources say 40°L is the minimum required for self conversion. That means it could barely handle its own starches before you threw 28% flaked corn in the mix.