hi everyone! thanks for all the suggestions and comments! really helpful, and i have some updates.
spoiler: i’ve tuned it so that it’s got 80% of its power back, with only quite rare little backfires! here’s how we got there–
i tested the vacuum with a mityvac i have around, and the results were interesting. the main “symptom” is that the needle flutters very quickly back and forth about 1 inch Hg. this could be that the gauge doesn’t have a damper, apparently, but also might be useful info.
otherwise, at idle and warm the vac is around 17-18 inches. not great, but not bad afaik. rev quickly and release, and it drops to zero then back up quickly to around 23, then settles back. so – no clogged cat. maybe worn rings. rev high (no tach, but in vicinity of 3k rpm by ear), and it goes down on accel, stays level around 18 or so when even revs, then goes up a bit when decel. seems normal. otherwise, no big issues (eg. spontaneous drops in vac, etc.)
so. if the flutter isn’t an artifact, then i think it could mean one spark plug is underperforming, or a valve is a bit tight or got friction or something.
so i start to explore the sparkplugs. bingo - the #1 plug is more carbonized that the others. testing the gap, it’s also a lot smaller – like .030 when the others are .039, which is spec for that plug. (maybe the #1 got bumped a lot as i was pulling it over and over to get TDC correct.)
however – spec for the vehicle is .044! i check, and the original plugs before i put in new ones are also at .039, so it’s been running with subpar spark the whole time.
gapped the sparks, and there’s a distinct improvement in performance. can accelerate up hills, much less bucking and hesitation on accel, and much fewer backfires (which only happen at low rpms under load).
so this is exciting!
after gapping the sparks, the flutter in vacuum is less but still present. when i rev high, it sometimes goes away completely, but then back at idle. unlike previously, it seems as if it’s mostly at the high point, then once per cycle (ie. per crank or cam rotation) it drops about 1 inch. this makes me think maybe one of the plugs is still acting up, or maybe a valve has problems.
anyone have suggestions for how to further explore this?
at this point, with how well it’s now running at correct 7 deg BTDC timing, i’m thinking the timing is no longer a likely cause of remaining problems.
(in related news: on the suggestion above, i thought to clean the MAF. pulled it and sprayed with CRC MAF cleaner, waited for it to dry, then put it back in and it seemed to make things better! wow! THEN i read the fine print that said not to use the MAF cleaner on karman vortex MAFs like in the mitsubishi – it can destroy them! argh! but things seem fine so far, knock on wood. lucky i have a spare from the other vehicle.)
again, thanks for everyone’s input! appreciate further thoughts!