I have gone back to the January edition of gathering of Hosts and applied various lessons learned. The results are now ready for a play test, hopefully one by me this weekend. We will be on puppy watch so I can't go far anyway.
Apart from tightening up details and language, the big change is to replace a rally test and a break test with automatic disorder if suffering 25% missile casualties in 1 turn or losing a round of melee by suffering 50% more hits than inflicted. A compulsory rally/break test for all disordered units then closes the turn. This avoids most of the double jeopardy issues with a separate test but gives a small chance to recover in melee while putting levies, under strength units and melee losers at risk of panic.
It also allowed me to simplify the movement rules.
The old figure rally rule was both fun and tiresome and while it sometimes worked, I think this will give me the same general end result with less fuss and more reliability. Poor units will tend to fall apart, good quality heavy units can withstand a tremendous amount of missile fire before being destroyed but are at risk of temporary disorder.
The updated rules are available on Google Docs.