Jay, I just tweaked a set of BBC heads for a local guy, and the exhaust was 1.880", which is fairly common and easy to buy. The ports were smallish, but still could be made to reach close to 300 cfm, and with a little work, I am sure they would have. I think you are on the right track for maximum flow potential at anything over 2.350", and the 1.900" is a good compromise for unshrouding. The 1.940" exhaust valve starts to get heavy in inconel. For a 500 cfm intake, you need in the range of 350 cfm on the exhaust, and a header will pull a port up at least 20 cfm if the shape if good. Joe-JDC