
)The idea of the the Bypass design is that initially the LM317 only supplies output current. At about 60mA, the 0.6V drop across R1 begins to turn on Q1 which in turn drives the output transistors, suppling load current. The values of R1 and R2 are not critical, they just affect the current at which the bypass action begins.
As load current is increased, the LM317 should not need to supply much more than the 60mA. This can be checked by monitoring the voltage drop across R1.
The circuit could be oscillating, check with an oscilloscope if possible. I would remove the 10uF capacitors and shift the 100uF to the left side of R1.
Due to non-ideal layout, the LM317 might not be seeing the actual output voltage. All it cares about is the ~1.25V across R4.
The LM317 will do its best to regulate the voltage between its output pin and the bottom end of R5, as measured at R5.
As this is an issue regarding regulation under load, i am no longer bothering to tune the pot as i change values, so i just record the values for Vreg output under no load than then under load. with the changes above, the output variance was 12.39v@0A -> 11.27v@5A.
I agree Vovk_z, which is one of the main reasons i wanted to change my historical approach to doing this, over to the one that is in the ti.com datasheet. Other than it using 2N2905 and TIP73, it is fundamentally the same, and is the reason that I started off with a 5KΩ as the base resistor.
if i was to set R1 as 22Ω, is there a formula for calculating R2?

Thanks again xav and PCB. have to say, as a first time experience in this forum, everyone is amazing and i cant thank you all enough!
so... oscillation. This was absolutely a factor, and not one that i thought would be so profound in terms of the regulator's ability to do its job.
moving the 100nF to the left of R1 (as it is actually shown in the datasheet from ti), immediately made a positive improvement, but i went 1 step further and put the 1uF tant there instead. interestingly, i found that the output voltage under load lifted considerably if i added the 100nF back in between R1 and R2. Sounds a lot like the RC suggestion from PCB.Wiz
@0A
output=11.97v
32CG
-Vc=53mV
It is interesting that in your example, they dont include an "R2" at all on the base of the PNP's. is this a point of significance to consider?
Sorry to be a bit off topic - I've been running one of my PSUs with a 3A version of the LM317 for 25y already and I am pretty "unhappy" with it - as it will be killing any wrongly wired experimental constructions. I smoked many precious chips while using it. This type of PSU is good for fixed voltages with well defined loads (like stand alone stuff).
I would highly recommend you a power source with a max current setting, at least 2 positions as the minimum - like 50mA (smoke test) and full.

With that said, looking back at your original circuit and comparing it to the datasheet (page 17 of this data sheet: https://www.ti.com/lit/ds/symlink/lm317.pdf) shows that you have a 1uF tantalum capacitor on the output where the data sheet shows 47uF. The increased output capacitor in the data sheet is not necessarily surprising as the addition of the external transistors are giving a significant amount of current gain that can throw off the loop response of the LM317T, hence the need for additional capacitance at the output to change where the output pole comes in to stabilize the loop.
The LM317 will normally be able to function without a lot of input capacitance, with 22 ohms from IN to the bulk input capacitors is usually low enough impedance for the regulator to look into. BE CERTAIN YOU HAVE ENOUGH BULK INPUT CAPACITANCE!!! You have two circuits that you show in a post, one shows 60,000uF of bulk capacitance and the other shows none. You need to remember that the wires from your supply to this circuit will act as an inductor so if you don't have enough bulk input capacitor the double pole formed by the LC (or the output pole of the supply feeding your circuit) can be a high enough frequency that the LM317T cannot reject it. I have seen more than one circuit where the impedance at the input of the regulator input was either too high or a double-pole was formed that was close to or above the unity gain frequency of the regulator and the entire circuit oscillated.
The input to a positive NPN regulator needs to be decoupled if it is located far from the bulk input capacitance. Otherwise it is not required.
In this case it needs to be decoupled because of the input series resistance of the boost circuit.
Solid tantalum capacitors have better high frequency characteristics, so when used for frequency compensation at the output of a regulator, can be a fraction of the capacitance of a standard aluminum electrolytic capacitor.
The boosted design should have more output capacitance however.
I think what you are confusing between solid tantalum and aluminum in regulator loop compensation is not their high frequency characteristics but instead the effect of ESR. A pole is formed using the output capacitance and is directly related to the output capacitance amount. Without ESR, if you have a 10uF aluminum electrolytic it may set the unity gain bandwidth of the regulator at 30kHz and a 1uF solid tantalum would be 300kHz. What ESR gets you is a zero to come in and raise the phase so that you get a bump in phase margin where the gain cross unity. The downside of the added ESR is often a larger transient deviation for the same load step--less C means bigger voltage transient together with higher ESR means more voltage drop for the same current. Things can still be stable, and in some cases the additional bandwidth that comes from a smaller capacitor may give a better response, but it's not always the case.
I think what you are confusing between solid tantalum and aluminum in regulator loop compensation is not their high frequency characteristics but instead the effect of ESR. A pole is formed using the output capacitance and is directly related to the output capacitance amount. Without ESR, if you have a 10uF aluminum electrolytic it may set the unity gain bandwidth of the regulator at 30kHz and a 1uF solid tantalum would be 300kHz. What ESR gets you is a zero to come in and raise the phase so that you get a bump in phase margin where the gain cross unity. The downside of the added ESR is often a larger transient deviation for the same load step--less C means bigger voltage transient together with higher ESR means more voltage drop for the same current. Things can still be stable, and in some cases the additional bandwidth that comes from a smaller capacitor may give a better response, but it's not always the case.
I was just going by old application notes which suggest using solid tantalum capacitors of 1/10th the size of an aluminum electrolytic in this application, with the high frequency impedance being what is important. My own tests show the ratio to be more like 1/4 but NPN output positive regulators are very tolerant.
This comes up more for the negative regulators because they operate with a common emitter NPN output than with the positive regulators, but the positive regulators still benefit from better transient response when the output capacitor is included even though it is not strictly required. The negative regulators *must* operate with an output bulk capacitor.
With the current boosted circuit, I would include the output capacitor and increase its size proportional to output current. I have always gotten good results with this circuit but others seem to find it temperamental.
Off-Topic...
One drawback regarding linear three-terminal regulators is that the internal reference is not bypassed (with a capacitor).
Thus, noise generated by that reference will find its way all the way to the output of the regulator circuit.
Attempting to supress this noise using (large) capacitors may lead to increased risk of self oscillation.
I know that my entry is a bit off-topic but I would recommend taking a look at the old 723 regulator. It may not be the best in all
cases but the basic functionality with a separate decoupled reference (6.2V - Zero drift vs temperature), its buffer and a separate
OP-Amp where the regulator loop can be designed and optimized and also with the posibility to optimize the time constants/frequency compensation
of the regulator. There are many circuit ideas on the internet that also shows how to implement foldback current limiting, a feature that
saves the series pass elements from getting overheated during prolonged short circuit conditions.