I thought I had it fixed, loaded up sim adjusted course, cruising along on the surface enjoying the "ocean". Hurray no passing thermal layer.
Go to flank speed make a hard starboard turn,

PASSING THERMAL LAYER
This is becoming some kinda twisted nightmare

PASSING THERMAL LAYER
You have got to be kidding

PASSING THERMAL LAYER
Either Vanilla 1.5 fresh install, completely clearing out everything I can find on the machine, or with mods PASSING THERMAL LAYER . Find that crewman now
I really do not what to do now except maybe completely rip out windows to find him