finally after much much much fiddling this worked:
Resolve DNS with test then check Plex Settings
1. RESOLVE DNS
Step 1: Quick sanity checks first
Do these on the iPhone and the PC.
iPhone
Windows
nslookup config.claspws.tv
nslookup repo.claspws.tv
curl -I https://config.claspws.tv
curl -I Artifactory@ip-172-31-33-164 :: Welcome
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If you get IPs and fast HTTP headers, DNS is fine.
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If resolution fails or hangs, fix DNS below.
Step 2: If both resolve, skip DNS fixes
Go straight to Plex items:
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iPhone → Settings → Plex → Local Network = On.
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Plex Server → Settings → Network → Secure connections = Preferred.
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Allow DNS rebinding for plex.direct in your resolver if you use one.
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Enable hardware transcoding. You already set NVIDIA.
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When testing, check Plex Web → Status → Dashboard for Playback and Connection.
Step 3: If either domain fails, then do DNS changes
iPhone
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Wi-Fi → tap your SSID → Configure DNS → Manual → 8.8.8.8 and 8.8.4.4 → Save.
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If you run Pi-hole, NextDNS, AdGuard, or Cloudflare Gateway, allow-list:
Windows
GUI path:
ipconfig /flushdns
PowerShell option:
Set-DnsClientServerAddress -InterfaceAlias “Wi-Fi 2” -AddressFamily IPv4 -ServerAddresses 8.8.8.8,8.8.4.4
Set-DnsClientServerAddress -InterfaceAlias “Wi-Fi 2” -AddressFamily IPv6 -ServerAddresses 2001:4860:4860::8888,2001:4860:4860::8844
ipconfig /flushdns
Browser Secure DNS
Router (only if you manage it)
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Set WAN and LAN DNS to Google for IPv4 and IPv6.
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Disable router DoH or content filters, or allow-list the domains above.
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If you use a resolver with rebinding protection, add plex.direct to the exception list.
Step 4: Retest
That’s it. This order tests config.claspws.tv and repo.claspws.tv first. You only touch DNS if those fail.
2. PLEX SETTINGS
What we changed for Plex casting
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Confirmed DNS isn’t blocking Vizbee: config.claspws.tv and repo.claspws.tv resolve and respond on both PC and iPhone.
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Plex Media Server:
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iPhone: Local Network permission for Plex = On.
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If you later use a DNS filter, keep an exception for plex.direct to avoid rebinding issues with secure direct connections.
If casting stutters again
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On Plex Web → Status → Dashboard, check the session labels:
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Aim for Direct Play/Direct Stream and Connection: Direct.
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If it shows Transcode, your server must keep up. Lower cast quality or remux to MP4 for Direct Stream.
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Change Plex app Videu & Audio Lcal Quality & Wi-Fi Quality down till stutter stops.
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Keep Chromecast and iPhone on the same 5 GHz SSID and make sure mDNS is allowed.
That’s it. Your DNS is set to Google, and the Plex changes you made are the right ones for the new app.
Important note about DNS:
Cloudflare DNS can still be in use even if the checks above look fine. For this guide, set DNS to Google first on iPhone, Windows, and your router, then retest.
Use 8.8.8.8 and 8.8.4.4. For IPv6, use 2001:4860:4860::8888 and 2001:4860:4860::8844.
Update:
Cloudflare DNS was the culprit. After switching to Google DNS, I flushed DNS ipconfig /flushdns
on Windows, and it still took about 30 to 60 minutes before casting worked. This delay happens because iOS and some network devices cache DNS internally, so the old address can be used until the cache expires.