I should have been more clear. Too much catalyst dissipates with an acrid, almost vomit type odor, often accompanied by a pinkish color shift and/or haze. This is a different smell than the normal outgassing of formaldehyde. In my opinion, companies that use a diluted catalyst are just trying to sell more product. A gallon of catalyst at 3% lasts a lot longer than a gallon at 10%. 3% ratios are not difficult to measure with reasonable accuracy.
Crew weight. There is a wide range of crew weights that is competitive in the Viper 640. The average of all crew weights at the 2015 North Americans: 550 lbs. Crew weights ranged from a low of 490 (#10) to a high of 650 lbs.
The dry weight of a spacecraft is the mass of the spacecraft without oxidiser, fuel or other consumables. It is not necessarily the same as burnout mass, as burnout mass may have residual propellant and consumables.