Have you checked the bias on your amp? It's very easy to do on this amp and could be at least part of your problem. Possibly some new/better tubes might help as well.
I tend to only use the green channel on the ultra gain side and keep the gain relatively low(10-12 oclock) and for my purposes(classic rock) it sounds really good. Like others have said maybe boosting with a pedal from this point might work better for you than adding more amp gain.
Also, wondering at what volumes you are playing at? I'm guessing on the lower side with the kids at home. Turning it up if you can will oftentimes tighten things up and give you a very different/better tone.
I have not checked the bias, though I have watched some videos on checking it, replacing tubes and speakers. Seems easy. Maybe I need to buy a multimeter this evening lol. What is the recommend bias setting? Side note, I’ve considered everything in terms of replacing power tubes, speaker etc. (But am hesitating only because if none of those work out it’s just sunk costs)
In terms of using OD/Distortion pedals I’ve had a fair few in the last month LOL (Revv G3, Iron Horse, Rat, Westwood, Tubescreamer, Blues Driver, Soul Food, OCD) Where I’ve landed with relative content is the Strymon Riverside and Earthquaker Plumes. (OP Amp Big Muff for fuzz) TBH I’ve never quite been content with any of them into a Gain channel on the DSL, rather than Just into the clean channel. I think I probably like the Riverside because it is so wonderfully varied with it 5 gains stages and It’s really smart underlying DSP for the EQ band that make it hard to dial in “bad” tones, and does a relatively good job masking underlying inability to dial the amp EQ in.
As for volume, this sucker is LOUD so I don’t think I’ve ever gone past 11 o’clock on the channel volume in 40w mode. (A great way to clear out the downstairs of my house haha) Generally I stay around 9-10 o’clock in the channel volume, and sort vary the masters between noon and maxed, because generally it seem the amp wants purr a bit more with the masters cranked. I thought about getting an attenuator so I could get it really cooking, but again it sorta goes back to my sunk cost worries. (And me knowing that I should be able to get something going even at the levels I generally play at)