Pleased to announce that I have solved the problem.
Thank you everyone for your advice, particularly
@El_isra for your help and for coding the dummy test program, I would've been completely lost without you. No doubt this will be a great resource for anyone else wanting to troubleshoot
I ran the DTP and was still returned to browser, so encryption problem I guess. I wondered if maybe my memory card was bust so I decided to dig around for a different one. I installed freemcboot, took osdmain.elf, and decided to retrace the exact same process I used in the first place to make sure the problem wasn't with KelfTwinSigner. surprisingly it worked perfectly.
I thought this was unexpected so I checked the file from the other mc again, in the output on my cmd, I noticed the kbit and kc were similar but not identical. So I guess I found the issue, my original memory card must be a bootleg or something, there's nothing visually that would indicate that but I got it from ebay so there you go.

I highly highly recommend
@El_isra 's Kelfbinder, It is an incredibly well made program. Once I got my head around what I was doing, I could see how it is a much easier and faster process than using KelfTwinSigner. Hopefully someone is able to make a tutorial soon, so that it can be even more accessible to the community.
Thank you so much guys
