You absolutely have to know the surface areas of your parts....
Length x width for square/rectangle areas,
Pi (3.14 inches) x the radius squared (radius x radius) for circular areas,
Pi x the diameter for measureing around a cylinder or round bar.
Don't forget to measure the insides of the parts too.
I ano mostly paintball gun parts, and have an accurate list of every part I've ever measured. Now when I do a job, I just reference my cheat sheet.
Also, the acid to water ratio for your ano tank, temperature of the electrolyte during anodizing, and target current density all have an effect on the quality of the results and how much voltage is drawn. If your ano tank is above 75 deg F., you may disolve the anodic layer as fast as it is grown.
M_D can speak to the Ti racking, but why are some of the fingers aluminum? You realize that any aluminum racking parts need to be stripped after each use.
Once you get your SA figured out, maintain exact electrolyte temperatures, and account for the surface areas of your racking system, I'm sure you will have much more consistant results.
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