I can understand your frustration, but you keep comparing "modified" engines so you have no baseline for performance. It's too dark for me right to use a tach, tomorrow afternoon I will take a brand new 46LA-RN out of the box, put it on a test stand, and see what it does.
OK, here we go:
Prop original rpm (4-2 point) rpm (peak)
Top Flite 11-5.3 (from 11-6) 9600 10400
APC 11.5-4 (95 NATs) 10000 11400
Bolly 11.5-4 (from 12-6) 10000 11200
Bolly 12-4.5 (from 12-6) 9600 11000
This is with a bone stock, completely new ,straight out of the box 45 minutes ago, OS-46LAS-RN engine with no break-in and now has a total of about 2 minutes. Plug is whatever came with it. Fuel was Powermaster 10% "Air", unmodified, air temp 76 degrees, altitude = 15 feet ASL, pressure alt 100 feet, humidity 33%. Not "disassembled-cleaned-lubed", head screws per factory, backplate per factory, no idea what head shims (factory). Venturi is STOCK 7.2 mm (~.283xx), spraybar is STOCK 3.5mm OS nozzle, needle is STOCK backplate remote needle,
Engine was *extremely tight* throughout, and clearly getting better with each run. It did the typical thing, it was *boiling hot*, particularly the front end. That is the normal reaction to it still being tight. It would pick up maybe 4-500 RPM at the 4-2 break point, and at least that much on the top end, when fully broken in. The only issue I had with it was my fuel line splitting at the tank, which caused me momentary confusion about where all that air in the line was coming from.
The prop selection is as close as I had to your test prop, and then 3 props that I would consider running on a regular 650-square inch airplane.
The 11-5.3 is actually a cleaned-up Top Flight 11-6 Super-M that I last ran on a Fox 35 at about 2000 less ground RPM (in *1979*), 5.3 is the measured pitch.
The APC 11.5-4 is the original 11.5-4 "narrow" that Billy asked APC to make for the OPS-40, and that I ran and qualified at the 94 NATS on my 40VF.
The Bolly 11.5-4 is made from a Bolly 12-6, this is also a 40VF prop, maybe I ran this prop at the 98 NATs.
The Bolly 12-4.5 is an old fiberglass 12-6, depitched, which I definitely ran at the 96 Golden State contest, which I won, and *may* have been the prop Ted used on the 46VF on the original Trivial Pursuit. This is clearly too much for the 46LA with no break-in, *maybe* it would be OK with it broken in, I would start with it at 5" for most applications, which would be a lot easier on the engine (because the in-flight RPM would be 4-500 RPM lower).
If I was going to fly an airplane your size with this engine, I would probably start with the 11.5-4 Bolly, adjust the pitch up if it was too "flat" and down if it was too responsive in the maneuvers.
I suppose the point is taken - this BOX_STOCK engine, not broken in and, honestly, sounding distressed because it is still so tight, greatly outperforms your "expertly modified" version, and most of the ancient former hot-rods, and a few hundred RPM off the best one you have, and will certainly get much better with break-in.
Of course, this is just ground testing, but stock 46LAs are know to be exceptional at flying stunt planes, power notwithstanding, much better than any HP 40 Gold Cup I ever saw - all of which I routinely beat with my weak ST46, back when they were both viable competition engines.
Brett