I had the same problem- here's what you do-
Step 1- dump the auto cal, and gro straight for manual.
-calibrate the stick per instruction, then save the file, and then apply the settings to the device.
Step 2- open the "Hotas Cougar" from your control panel- this brings up a great monitoring tool.
-play with your stick at the edges, watch your axes- they will flutter. That's okay.
Step 3- fire up HOTAS CCP, and adjust deadband to approximate "play" area - (mine is currently at 9%).
the idea is, you want the stick to begin registering input at the end of the free-play area. Idealy, you should be able to wiggle the stick from here til the cows come home without getting a single shift in your axes monitor.
-CONSIDER THIS-
Once you've done the above, the axis curve may need to be adjusted- what you want is for the zero point to be at the edge of deadband. So, when you hit the deadband, you have to move it ever so slightly against the tension for very gentle maneuvering.
Currently, my deadband on both X and Y axes is at 9%, with a curve offset of -3. Works great.
Lemme know if you have any questions.