I understand thefirst part...flash .CHK file from netgear stock GUI after 30-30-30 reset..but then how do I update to latest version using the BIN file??
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This only really applies to the R7500, R7500v2, and R7800 -- which require an "initial" flash file.
Depending on the version of the initial flash file you are using, you may need to perform a firmware update within DD-WRT, using Kong's newest .BIN file, to get to the latest version.
For the R6400, you can use the .CHK file from factory and you're all set; that version could also be used to upgrade from within DD-WRT.
R6400 does not need 30-30-30 its an arm router you just flash the chk file then set admin name and password then clear nvram via telnet use putty to telnet to router