Where to start...where to start?
First, Caswell only supports the Low Current Density process of anodizing, so all my responses will be based on this process. Based on your post, I'm not exactly sure where you got the information you used, although I suspect it was from the 'net'..
I'm not familiar with the use of nitric or sodium hydroxide use/concentrations since I use the Caswell products and just follow their instructions.
First, your anodizing temps are too low, if they are in F. If they are in C, then they are too high.
For LCD, the ideal temperature range is 70-75F, with 72F probably being ideal.
Clothing dye is for clothes, not anodizing. Sometimes it will work, but usually it does not. It also fades quickly in sunlight since it is organic.
A quality dye, specifically for anodizing will go a long way to getting a good color penetration.
Your electrolyte is too concentrated. LCD uses about a 5% concentration (by volume, not weight). When the electrolyte is too concentrated, it eats away the anodized surface faster than it is created, resulting in no coating.
Using a battery charger is just asking for trouble, IMO. Its difficult to control the amperage and usually doesn't have sufficient voltage. Fibergeek has some posts here about using a VCCS to give some control over the charger, but I haven't bothered. You can buy a supply cheap enough that its not worth the time, effort or potential issues involved.
There is effectively no difference between 6061 and 6063 as far as anodizing is concerned.
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