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@Dammit I'd be very surprised from what you're saying if that isn't excess grease blocking the port. You'll also find that there isn't any oil on the top of the air spring either.
I suspect I know the answer to this - my girlfriends bike has a Fox34 on it, which we set to the pressure value in the little quick reference chart on the fork leg. She never gets more than 50% travel. I borrowed her bike and rode a short but very rooty and moderately steep section of trail and I got the same travel that she does. I'm 20+ kg heavier, and load the front of the bike quite a lot. Fork buggered? Needs a service? Something else?