bad pixels gone:
o formatted and installed chdk on a 4gb sdhc card with ct 1.42
o took a dark frame raw pic
o made a badpixel file using show_bad.exe
o converted badpixel file to unix format and removed the "= xxx"'s in editpad lite
o saved as "badpixel" not "badpixel.bin"
o copied badpixel file to the chdk folder on the card
o set camera menu item RAW Parameters --> Bad pixel removal to [Averag.]
o turned Save RAW off
now saving in super fine jpg's with no bad pixels ... very happy