Here are the steps taken and results:
1. Perform user calibration using 5.5.9 Calibration Assistant app on "R" device running R1.1.0 (not the latest firmware)
Result: Augmentation misalignment observed between left and right eyes. Seen when verifying the calibration on the last step of the workflow with "red rectangle calibration". Also seen when and when running Stereo Rendering sample app and using same user calibration blob.
2. Perform user calibration using 5.5.9 Calibration Assistant app on "D" device running D1.1.2 (latest firmware version)
Result: Augmentation aligned perfectly between left and right eyes when verifying the calibration on the last step of the workflow with "red rectangle calibration". Further verified wihenh Stereo Rendering sample app and using same user calibration blob.
3. Perform user calibration using 5.5.9 Calibration Assistant app on "R" device running R1.1.2 (latest firmware - was able to finally upgrade)
Result: Augmentation aligned perfectly between left and right eyes when verifying the calibration on the last step of the workflow with "red rectangle calibration". Further verified wihenh Stereo Rendering sample app and using same user calibration blob.
Bottom line: I cannot recreate the "bad" user calibration reported here when running the lastest firmware.
For supported see-through devices with stereo display, best AR registration results will be achieved when running the Vuforia Calibration Assistant. The user calibration data created should be applied when running the app on the BT-200.
https://developer.vuforia.com/downloads/tool