Pete,
Yes, I upgraded to 3.48 so that's not an issue. My FSUIPC.ini subsection for the joy stick calibration is as follows:
[JoystickCalibration]
FlapsSetControl=0
ReverserControl=66292
MaxThrottleForReverser=0
AileronTrimControl=0
RudderTrimControl=0
CowlFlaps1Control=0
CowlFlaps2Control=0
CowlFlaps3Control=0
CowlFlaps4Control=0
SlopeAileron=0
SlopeElevator=0
SlopeRudder=0
Spoilers=0,16300
Flaps=163,16300
Throttle1=-16380,83,898,13938
Throttle2=-16380,246,572,15731
Throttle3=-16380,83,898,11982
Throttle4=-16380,83,735,13123
ExclThrottleSet=No
SepRevsJetsOnly=No
Reverser1Control=66422
Reverser2Control=66425
Reverser3Control=66428
Reverser4Control=66431
I tried several different aircraft and got exactly the same result. At all flap settings except the flaps 25 position FS goes to flaps 30. At flaps 25 it goes to flaps 5.
One potential issue that I haven't mentioned is that I am using the GoFlight GF-TQ6 throttle quadrant, now just using their joystick controller married to my regular throttle/flaps/speed brake set. Is there something in the GF deal that I need to change or delete?
Also, a slightly different issue but I haven't been able to calibrate the thrust reverse either but let's get to the bottom of the flaps setting first.
Cheers
Jon