Of course I've been up all night! Not because of caffeine, it was insomnia. I couldn't stop thinking about coffee.
It has never been clear to me when the surge actually happens. Certainly the cheese is added immediately but does the surge happen before combat is resolved? The rule book on page 15 when describing when surges happen simply says:
When the minion cheese wheel fills up with 6 or more cheese tokens, a surge triggers. Follow these steps...
I suppose immediately performing the surge makes sense but it does mean that you could loose a chapter while delivering the killing blow in a final battle, which seems a bit sad face