I have looked at the pictures and the suggestions made, and agree they are all good suggestions.
- get plenty of air to the engine is a must. If you tried with cowl off, that eliminates that for now, but you will still need to make provisions for plenty of air in AND OUT when running with that cowl on.
- set the pipe with the 100 degree header as Scott suggested. Don't leave too much header inside the pipe. Try to limit the amount sticking in past the second Oring to about 1" for testing...when you find the sweet spot, set it to have about 1/2" sticking past the second oring.
- make absolutely sure there is not leakage at the 2 Orings in the pipe flange (the part that seals on the header). Water leakage in here will allow water into the tuned pipe and act as though the pipe is much longer, in turn never giving max RPM.
- I don't like the look of the 4th picture (the drawing)...I hope that's not really how the transom looks! Are the sponsons offset like that for real? With the port side being deeper than the starboard side? Maybe so, I've never seen one like that. In any case, try setting the strut up so that the center-line of the propshaft is about 1/2" up from the bottom of the sponsons and tune up or down from that point. This should allow the prop to free up enough. It looks like the strut has no skeg. You may have to get a skegged strut to stop the propwalk when running the prop high. Most cats prefer this. I also typically mount my strut anywhere from 1/8" to 1/4" to the right of center on cats to help with propwalk. Keep the strut flat (no negative or positive angle) for initial testing. Even when tweaking, there should never be any more than 1-2 degrees one way or the other depending on boats.
- if you have a 6717/3 stock or in 400-410 range that would be good for setting the boat up. if not, tell us what you have and we can probably suggest one out of the bunch to use as a setup prop. Maybe you have something in your box that would be better than the 670 if the setup is correct.
- Also, tell us what carburetor is on your engine and the needle settings you have it set to right now.
BTW, What kind of cat is that? PPB?