I'm using my HD500 with the 4cm to use my amp's preamp for high-gain sounds, and the HD500 for overdrive sounds, clean sounds, and all effects. I'm then using my amp's power amp and cabinet for reinforcement.  
  
Here's the trouble:  I get my clean (Blackface Vibrato, full amp) patch sounding just the way I want, and max the channel volume (it's the quietest patch).  Then I adjust my OD patch (PhD Motorway, full amp) to match the Blackface.  Now I adjust my amp's preamp to get its level to match the clean and od patches- by dropping the preamp volume/master volulme.  Doing this, I'm getting a lot fewer dB's at the speaker than I would get if I was running my amp without the HD500, there's so much volume drop that I'm having trouble getting back up to rehearsal/gig volume, even with the HD500's Master maxed.    
  
Setup/testing notes: 
The amp is a Genz Benz El Diablo 60TS head, which has a serial, post-master FX loop.  GB's documentation is unclear if this loop runs at +4dBu or -10dBv. 
I run the HD500 FX loop in "line" mode, with a -7dB send and a +8dB return, per perapera's research. [updated Link]
Before using the HD500, keeping the amp's channel volume at about 50% and the master volume at about 30-40%, I was able to get good rehearsal/gig volume.
I'm matching patch levels using the HD500's looper (pre-processing) and an iPhone dB meter at bedroom and rehearsal volumes.
  
Solutions I've tried: 
Running an Xotic EP-booster (maxed, for about +20dB boost) between the HD500's output and the amp's FX return.  This provided adequate levels, but I prefer to use the EP-booster before the HD500 (not maxed).	Using the "Tube Comp" model after my clean and OD amp models.  This provides adequate levels, but I'm unsatisfied with its effects on the clean patch's tone.
TL;DR version- My clean patches aren't loud enough to drive my power amp to rehearsal/gig volumes.   
  
Does anyone have advice on getting a squeaky-clean patch to match the level of a physical high-gain preamp? (no, I'm not interested in a new amp or a frfr solution)