I can't find any reason why the path would change except when MC could not find the configured path.
I suspect that the definition of the bolded works is at the heart of the issue.
The problem seems to be PC specific. If drives are allowed to sleep, are slow to start, have small buffers, or the PC has a slow SATA connection, or the motherboard is slow to handle hard disk activity or communicate hard disk readiness state, or the BIOS isn't the best, or . . .
You get the idea. There is a lot of stuff in the chain from receiving a signal in a tuner to writing the recording on the disk, and a lot of it is hardware and/or related drivers, chips, etc.
The fact that the default directory was created on the same drive as the original configured directory would imply that the timing difference between first request and fall back to the default directory is enough for the configured disk drive to become available. That must be a pretty short period of time. Perhaps MC needs to wait just a little longer, or try the original configured directory one more time, and the problem may disappear. But that would have to be balanced against the need to start writing a recording quickly, before all buffers are full.
Note that I have my recordings saved to a non-OS spinning hard drive that is allowed to sleep, and I haven't seen this problem.