Bean to bar viscosity after adding sugar
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Yes, cocoa butter will thin it back down. When you say "quite a bit of cocoa butter in them naturally" do you know what the fat level is? Beans can range for 45-55% fat and the fat can have different hardnesses (melting points) so two beans with the same fat content might have different viscosities at different temperatures.
Limiting the number of variables makes sense to some extent but if, by eliminating a variable, you make the basic process much more difficult then I would add in the other variable - the added cocoa butter - so that at least processing and molding can proceed.
You might also check to make sure that the sugar is absolutely dry. One way to do that is to prerefine it in a food processor. If moisture starts to form on the lid then the sugar is not dry and the small amount of moisture in it could be binding with the chocolate, thickening it up.