I don't post on here a lot anymore so I'm doing this more often than I ever thought I would, but in case anyone was following this and could learn from my experience...
The Navien boiler apparently has an integrated air bleeder to get those last little bubbles out... and it certainly works.
Long story short, I actually discovered a leak - that's where the noise was coming from - tiny little pinhole pissing in the basement and allowing air to enter. So while the auto bleeder was doing its job, and the makeup valve was doing its job, it couldn't keep pace with a leak.
I paid the installer to come out and bypass the segment with the leak because all the joints looked like crap, and now everything is silent, even with the circulation pump on the higher setting.
I think my summer 2021 project is going to be to replace the hydronic baseboards in my "problem zone" with brand new high output ones. I've been thinking about doing a retrofit radiant floor system, but found some really ugly, corroded joints and so I think the whole system needs to go... I'll scrap the copper and hopefully get a few bucks back. But I'm going to put Pex everywhere I can get away with when plumbing in the new baseboards, and try to get a few more feet installed in the room since right now with an outdoor temp of 15 degrees and a supply temp of 160, it's losing ground in this 400 sq/ft room even with about 40 feet of fin-tube baseboard.
Initially my idea was to add retrofit radiant floor because that operates at a lower temp, and I could use the return water from the baseboards to feed the radiant floor and keep the boiler supply temps in the 140 range at most, and be in the condensing sweet spot for the best efficiency if my delta ended up being around 20 degrees between the two systems. However, because the rest of the home is baseboard and I don't really want to put radiant floor in the whole house, I think it's best to put brand new fin-tube in the problem zone and see if that helps in the 2021/2022 winter. If not, then I'll look at adding radiant floor and replacing the baseboard in the rest of the house with radiant floor... at least on the first floor where I have easy access from the basement.
Anyway... late-night ramblings are done...