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Extracted BINs are Redump-identical again. The built-in reader called CHDSharp with cooked:false, writing full 2448-byte raw frames (data plus 96-byte subcode) instead of chdman's cooked DataSize bytes per frame. A single-track MODE2_RAW disc extracted as 546,178,176 bytes (SHA1 072ea00f...) instead of 524,759,424 bytes (SHA1 9b4c1b51...) while the CUE looked identical. Extraction now passes cooked:true, matching chdman extractcd byte-for-byte (subcode omitted, audio byte-swapped). Reproduced against Armored Core (USA) (Rerelease).
Verify passing for the bad rebuild is by design. A CHD built from the oversized BIN is internally consistent (232,218 frames instead of 223,112; 267,908,519 bytes), so both chdman verify and CHDStudio Verify report success. Verify checks the header hashes, not Redump: the header SHA1 (6dc714d9...) and the file SHA1 (3e1b20c5...) differ from 7-Zip's file hash by design. Delete BINs/CHDs produced by the broken extraction and re-extract.