My thought is that you might want to start using R a little more again. For those yellow mornings, I’d get back to 0.1u and see how he does. Lately, the 0.5u when he’s headed up isn’t helping much.
I know you are concerned with the amount of insulin he’s needing and the cost. I’ve linked Crystal’s SS a couple times before and it is a great example of how Suki used R very strategically to keep Crystal in blue without having to continue to increase the Levemir dose. You might want to take another peak at it and study it.