Cheers again for the replies. Just for a bit of clarification this is the pedal I'm using for signal splitting.
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I don't think there's too many phase problems going on, if there are they're ones ones that are having more of a positive then negative impact. The clean blend seems to have a decent phase coherency anyway. I use a sort of complicated setup, with a multiband comp at the start and splitting that for the really low end to get fairly well tamed. So I've got a thinner sounding clean sound; then with the pedal I use a tiny bit of very distorted low end, for a bit of a quiet but dirty sound without the FX loops; and my main sound is just clean signal with a fuzz going through the midrange FX loop, and the low end mixing back into the signal with the low end FX return.
In essence though I can get a really decent signal out of my cab with all those sounds, that I'm very happy with. I'd absolutely rather use a mic, and I've been able to record without a DI with no issues and got some sounds I'm really happy with even just in my spare bedroom 'studio'.
One thing I have noticed that is around 6k where I like a bit of pick attack, there's still some nasty fizzy artifacts, so perhaps it still needs a little more filtering. I think all in all it seems like a cab sim of some description is gonna be the way to go. I quite like the relative simplicity of the Radial JDX48, but the DSM pedals look cool too.
In a really ideal world I'd have a guitar amp for dirt. I use the same pedal for another band I'm in, and go out of the midrange FX loop into one and it sounds amazing. Can't imagine my band or a soundguy at a small gig will wanna mic 3 amps though!