Within the EU FP-7 iMars project, a fully automated multi-resolution DTM processing chain, called Co-registration ASP-Gotcha Optimised (CASP-GO) has been developed, based on the open source NASA Ames Stereo Pipeline (ASP). CASP-GO includes tiepoint based multi-resolution image co-registration and an adaptive least squares correlation-based sub-pixel refinement method called Gotcha. The implemented system guarantees global geo-referencing compliance with respect to HRSC (and thence to MOLA), provides refined stereo matching completeness and accuracy based on the ASP normalised cross-correlation. We summarise issues discovered from experimenting with the use of the open-source ASP DTM processing chain and introduce our new working solutions. These issues include global co-registration accuracy, de-noising, dealing with failure in matching, matching confidence estimation, outlier definition and rejection scheme, various DTM artefacts, uncertainty estimation, and quality-efficiency trade-offs.