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I finally was able to wrestle the old 2020 installs off and reinstall all the 2020.1's and see the same exact thing.
Add Insulation Spec to the criteria. That'll apply the Insulation Spec to the service you're drawing with.D/L ignores the Service settings for InsSpec.
Correction. It doesn't actually work correctly.It actually oversizes it too much, 24x24 duct changes to 26x26 inside dimensions, end caps and stuff like that size correctly, but straight duct gets too large using that method.
Now in Revit you have to draw with a service that has no insulation spec assigned and then assign it and it will upsize correctly. If you draw with a service that has it assigned, even if you unassign, then reassign it does not oversize it correctly.There are a multitude of issues at play here with this which didn't occur in previous versions.
How does the 2020.1 update affect Revit? Seems like Revit will do it's own thing as it doesn't even need EST.
Can you post a screencast video so I can test?
Regarding the end cap, I know they did some work around stepdown connectors a while back..I'm wondering if that's causing this.