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Puck hole

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First you need to see if the hole is centered over the puck, if not I wouldn't go much over 1".

If so leave about 1/16" to 3/32" which is better if possible.

Needs to cover the hole perfectly especially if not centered.

THDP's rarely are centered from what I've seen, and I have one.

I think my housing is a 1 1/16" hole.
 
Depends also on your turbo. My stocker worked fine with a 15/16" hole.
But with the 6131E, I had to bore it out to 1 1/4" before it would control boost down to 15#.
The THDP puck is 1 3/8" in size.
 
What size turbo is this being used on.
For a stock turbo I would never go above .900"
A friend and I experiemented with this a long time ago playing around with different sizes on a stock turbo. We had it opened as far as 1.25" and the problem you run into is having to make the actuator rod ridiculously short to make any usable boost.
 
1" hole works great for TE61, PT54, GT67, etc. I have never tried a 70 turbo, maybe that needs a little bigger hole.
 
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