His daughter was born in 1966. We've looked at all the immigration sites, passenger ships etc for different variations of his name (Dickens, Dickenson, Dickin etc). The British Library has helped me find all the Robert Dickens who were adopted in Liverpool during that decade, but none of them are him. I worked my way systematically through all the Robert Smith (my grandma's maiden name) birth certificates from Liverpool in that decade, none of them are him. Now I'm just getting boy Smiths with MMN Smith in the hope that one of them will be him!
We know he was my grandma's baby because of the DNA match with me, my sister and my aunt. We're looked at it every which way, but this is the only explanation due to the high match. The story about the sister Dorothy is anecdotal (via his daughter). Nothing concrete.
It is indeed a very frustrating puzzle!! Another anecdotal story was that he'd worked at a particular sheep station in Queensland - I found them and they looked in their records, and I had people from their Facebook page helping me look, but nobody had ever heard of him!