Tooldini,
It was a large star break total about 1 inch across. Had a nice crushed center and surface and sub surface cracks.
Naturally, we as repair techs would prefer if every repair turned out absolutely perfect and invisible (or nearly invisible). But the reality is not all breaks clear up the same - namely the type of damage as you describe (with a crushed center with surface and subsurface cracks.
From your description of this break, it sounds like there was a fair amount of damage within the body of the chip. I have run into this as well, and have seen the same result as you describe myself, and from other techs.
That is why we always say it will look 80 to 90 percent better, and is guaranteed to stop the break from spreading further.
A simple star with say four, five or six legs will fill quite nicely. But an impacted star with lots of underlying cracks and damage within the body of the chip will not clear up as nice as a standard star break because of the many, many fragments of refracted light being refracted on multiple planes.
... Kinda hard to decribe without a 3-d model of a pulverized star-break.
As long as you did the following, it is a billable repair, and you should feel confident in your work...
1. Removed possible moisure from the break.
2. Repaired the break according to your equipment manufacture procedures.
3. Have exhausted all other tips you have learned and agree that works from other techs on this forum, such as probing, flexing, heat??? etc, etc.
4. And your customer is happy with the repair.
Hope this helps,