Thanks all. Very informative. I hadn't thought the performance would be so affected.
To clarify, I'm not really filling the hopper, just tossing in 3-4 doubles worth.
I don't have a scale, and have never weighed shots -- not that I'm against doing so, but I haven't gone there yet.
I understand, therefore, that my doses and resulting shot volumes, timings, etc are impossible to repeat, or study clinically. But my methods haven't changed (other than using the grinder somewhat filled) and my results are quite different than usual.
As a years long single doser, I throw two scoopfuls of beans into the grinder, using the plastic spoon the europiccola came with. I'm guessing my doses are close to 14g.
Once I got the Vario, my first long-term exposure to a grinder with a timer, I experimented, finally settling on two 7 second "grindings" to fill my double. I take the filter out and tap between each. Yeah, a bit of work, but this greatly cuts down on flying grinds. This combined 14s has been enough to grind my single dose, and also completely empty the grinder.
When I started playing with a filling up the hopper a bit, I knew I had to cut down on my grind time, since 14s completely cleared the grinder of a single dose, but now I'd be getting as much coffee as it can grind throughout, instead of wisps near the end. Make sense?
Ultimately, with grinder filled a bit, grinding twice for 6.5 seconds seemed right.
After nearly choking the machine yesterday with a single dose and the micro ramped up to its finest setting, this morning I filled the hopper with 42g+/-, and ground with the micro back down to about halfway.
Some unexpected results. 6.5s produced much less than half the shot. (I know it's hard, since I can't measure anything, but when I was grinding per dose, 7s would grind roughly half of what I tossed into the machine.) Today, even after 13s, I had much less coffee in the filter than I expected, and ground a couple more seconds, just to get close to my accustomed dose. Inspecting the puck later revealed that my dose had still been a lot smaller than usual. (Jim, your speculation about inadvertent underdosing is borne out there, but this was not the case when I first filled the hopper last week and was getting the fast shots...)
The shot still almost choked the machine. Not quite as bad a yesterday, but close.
A couple of other observations that may or may not have some bearing. Today, the motor stopped on a dime at the end of the set timing. I didn't hear the motor slow down. When I'm running it in manual mode, or stopping it before it gets to the end of a set time, sometimes I hear the motor slow and stop. It's quick, but it's not a dead stop like it was today -- which is the way I think it is supposed to operate.
Also, I noticed the other day when running it in manual, that the grinder seemed to run for about a second before the timer started counting up.
Though it might not seem so, I'm really NOT looking for problems

and I do love the grinder, but I'd like to solve these mysteries, and obviously, if there is a problem, address it.
Thanks.