Some progress in the right direction was made this weekend. I was over a fellow guitarist's studio and he's big user of ToneX. I played my pedal straight into his PA (2x JBL EON 715) and it actually sounded pretty decent. Now, in terms of PA systems, mine is slightly higher end so I figured there's no way mine can sound so much worse. We rolled off a good amount of highs and lows to make it work. He remarked that he never liked the pedal run into a PA either but we got some surprising results.
The first thing I did when I got home, was to plug the One straight into the input of the PA and wouldn't you know, it sounds quite good. Then I hooked it back up to my pedalboard, but w/o the "post" effects after it, which are my Zoom CDR70, Diamond MLJr delay, and Catalinbread Talisman reverb, still sounded good.
It wasn't until I hooked up the post effects that the volume dropped significantly and the muffled sound became apparent. So one of those pedals is ruining the tone, I suspect it's the Talisman reverb because it has crap for headroom and is very picky about setups. I tried it on another board with just a DD-8 and Digitech Polara after and it was better.
Having no effects loop is going to be a challenge with this pedal because I'm applying verb, chous, & delay etc, after the cab, which doesn't quite sound right. Yes it has a built in delay and verb onboard, but I'm partial to mine and they are easier to control live. There's no way to turn off the delay or switch from a slapback to longer delays, for instance. If someone knows of a better way I'm all ears. At least I figured out the horrid direct tone for the most part...