Hmm. This xBmt seems to me to be anomalous in some ways, yet at the same time, kind of as expected:
First, I think there could have been a yeast problem. I see that the same yeast strain was selected for each batch; however, the same yeast starter was NOT used for each. This creates an additional unresolved variable. If one batch was not as healthy, or if one was contaminated, (or both?), this could explain part or all of the attenuation difference.
I also question how 19.75 lb grain could result in only 1.080 for 5 gallons with a standard mill gap setting. This... just seems like a poor mash or crush somehow somewhere. I recognize there's no sparge going on; however, I also can't help but challenge: just what percent efficiency was this, anyway? Less than 50?! I could be wrong but I believe most folks should be able to hit at least 50-55% brewhouse efficiency with no-sparge, with a standard mill gap quality crush. Maybe not, but that's the impression I get. I don't think this batch even hits 50% efficiency, but again I could be wrong and I have not run detailed calculations on it. Anyway, along with this...
By the picture, that just doesn't seem to me like a 0.039" gap quality crush, although I have no objective basis for saying so. Just doesn't *seem* right visually, based on my experience with my Barley Crusher. Maybe the mill gap was just a little off, and actually 0.045 or whatever? To be fair, the photographs might not be telling the whole story either. But if the true mill gap was not really known, then perhaps it would be better just to say "we don't really know what it was", and thus avoid any questions like this.
I might also mention: if your mill gap is relatively wide, then of course your beer is likely to be lighter and lower gravity than when it's set real tight. There's no shocker there at all. In the first case, the hulls are pretty well intact. In the second, they're pretty well pulverized and freed up more to darken the wort/beer.
A more interesting experiment to me personally might have been to aim to achieve almost exactly the same original gravity with each beer (e.g., 1.090 with 50% efficiency, and then 1.090 again with 60% efficiency). Obviously that didn't happen. But then you could actually eliminate the variable of OG and compare beers having more equivalent general color and body. Maybe another xBmt for another time!? Might not been the intent of this one, but maybe another time. It's one I want to run someday if I ever get a Round Tuit.
I have nothing but love for Brulosophy, but I also do see some xBmts better designed and documented than others. And that's fine. Please accept any and all criticism for the 2 cents it's worth.
One thing I can say: Even if all my other comments above are all wet, I can see one viable theory for a real explanation for the attenuation difference:
Reduced crush frees up fewer enzymes to convert yourn starches to sugars, as well as to break down said sugars from complex ones to more fermentable ones. So, to achieve more similar beers, perhaps either a longer mash would have been necessary, or (of course) a harder crush. In this fashion, the existing results are not terribly surprising to me. Poor crush --> not so many enzymes knocked loose --> poor conversion --> poor attenuation, and vicy-versy.