Sounds ambitious! You're doing it right with all the extra attention to detail. I'm too lazy at this point to put all the extra stuff into the engine since I'm not going all out on the power.
I hear you on the cold. I just kind of hibernate in the winter and it's just getting warm enough now for me to get interested in doing stuff out in the shop again.
I'm very disappointed that the outlet is only 1.5"... I was hoping it was up around 2" with room to hog it out a little more. I'm trying to get about 3.5 Sq in. area out of it so I can avoid building a manifold from scratch. does it look like there's enough room to hog it out an extra 1/4 " all around? Probably not since it's a factory piece made to pretty tight tolerances. Wonder if I could hog it out and then get it extrude honed? I just really want this project finished since I've been working on it for years now.