Peter:

I am not sure if I fully understand the process you are using....so I am
going to ask a dumb question, that may shed some light on the issue...

Is there, anywhere in electrical contact with Copper being etched any other
metal excepting Tin?

This sort of thing, selective over-etch, is classically seen when there is
some other metal, (Nickel, Gold, or???) than Tin in electrical contact with
the over-etched Copper, and also in contact with the etchant.

And if I am completely out in space with this question, please forgive the
intrusion.

Rudy Sedlak

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