Quote from: Joe-Bloggs on March 13, 2024, 11:53:08 AM

Because I notice with electrum when you use clipboard outputs and not save to files.
This keeps everything in hex. Which is just numbers and letters.

That only applies to exported fully signed raw transactions.
Even the file export (.txn) shows the same hex characters when opened as text.

If unsigned, Electrum will export it in PSBT format, via save to clipboard or file export (.psbt).

Quote from: Joe-Bloggs on March 13, 2024, 11:53:08 AM

If anyone can notice any problems with my process then please say.

Cold-storage Electrum setup supports QR Code export and scan,
That essentially fulfills your main goal to eliminate the usage of flash drive in your setup.

Is there any particularly reasonable explanation why you must use Bitcoin Core in your Air-Gap machine instead of another offline Electrum?