If you insist on electrolytic gold refining there are a few things you should keep constant.
First the cathode should be pure gold foil, scraping cathodes just is a messy pain, if it’s gold on gold all you have to do is rinse and melt. Keep the cathode size constant each time you change it because you want to run at a constant current density so keeping your anode and cathode size constant simplifies power requirements.
You can make up the gold chloride using aqua regia and boiling off the nitric, time consuming but do-able.
Keep the distance between the anodes and the cathodes constant, and perfectly parallel to each other. Make a fixture to fit over the beaker to hold the anode and cathode rods so they remain fixed and parallel. The reason for this is the distance between the anodes and cathodes affects the current density. When the cell approaches the end of its useful life, the impurities will plate out at different current densities than the pure gold so you want to keep the cells current density in the range you find to produce the purest gold.
Current densities can vary from very high when the free HCl is higher to very low. I set up cells running at 17,5 to 20 ASF with a voltage of 2.3 to 2.5 Volts.
Temperature can vary as well, 60 C is the hottest I’ve seen run I like 20 C.
Now for what you don’t want to hear, the reason the cell is ineffective for small production is all of the analytical work needed to run in the “sweet spot”, the range where the impurities in solution are low enough to remain in solution and not plate out on the cathode, thus contaminating your pure gold. Generally the kind of lab you need for control is only available to larger, better financed refiners.
I pulled Hoke’s book off the shelf to review a few facts and low and behold this is what she had to say, and I quote;
In this writer’s opinion, however, the electrolytic methods cannot be operated economically by the non chemist working alone. It is believed, further, that present electrolytic methods are rarely suited to small scale operation, even under the supervision of a trained electro-chemist. It is true that small systems have been set up – cells holding about a quart of gold chloride, for instance. In such a cell a trained worker can produce cathode gold of as high quality as he might desire, with mental satisfaction, (I like that phrase!) no doubt, but probably at unduly high cost, and the small cell will require almost as much attention as an acid system handling many times the amount of metal per day. And it is a matter of record that electrolytic systems of considerable size have been installed and later abandoned, usually for economic reasons.
I have found from practical hands on experience that refining small lots using classic aqua regia will yield less pure gold than running larger lots with the same methods. A lot of forum members experience this difficulty and have to revert to other options.
Inquarting is one of the pre refining techniques that will allow small lots to be refined to high grade gold. If necessary, add an oxalic acid precipitation to the aqua regia digestion after the inquarting process will give you what classical assayers called proof gold. Probably 99.99 fine or damn close.
I guess if you are looking for mental satisfaction, then go for it! You can also achieve the purity you are looking for with wet chemistry and in my experience, that brings mental satisfaction as well.