Seems we've now got to the root cause of the last aufs failure. /fs/aufs/i_op.c was the real problem. Although aufs6.6.4 hasn't been released, a patch has, & @peebee successfully made a 6.6.7 kernel. I compiled a 6.6.8 kernel & patch appears to be successful, as it boots fine & in brief testing runs ok.
stat.c & udba were pointers to the problem. It seems (at least for now) the process is: users find problems & specific errors, then a patch or workaround is released. Hopefully that is a only short-term scenario.
I also note that with the 6.6 kernels, if you run df, a mounted 'drive' of about 80kb appears: /sys/firmware/efi/efivars