Ok, guys, I've got some time this morning, so let's see if I can help you.
Dave has part of the question answered, ie the blade issues.
In the converter industry, to increase stall, you modify the vane angle on the pump (hub part of the converter) and also on the turbine of the converter. We also modify the stator to allow more oil to pass through it, by machining the openings in the stator. The clearances are very strict, and we do not increase stall speed by increasing these clearances. Industry standards dictate the following general rules.
A modified 12" diameter converter will give you 400 to 800 rpm stall over a stock converter, with MOST stock converters stalling at 1400 to 1600 rpm.
A modified 11" converter will stall approximately from 2200 to 2700 rpm.
A modified 10" converter will stall aprroximately from 2800 rpm to 3500 rpm.
A modified 9" converter will stall from 3500 rpm to 4500 rpm.
A modified 8" converter will stall from 4500 rpm to 65-6600 rpm.
A modified 7.5" converter will stall from 6500-7500 rpm.
You notice that the smaller the diameter, the higher the stall.
There are many things that must be taken into consideration in building a high stall converter, the engine, the rear axle ratio, tire size etc. weight of the car. etc., because improperly applied, a high stall converter can be the worst investment you will ever make.
I always ask my customer who is looking for a high stall converter, what he is using his car for, is it a daily driver, weekend cruiser, or is it mainly going to be for racing. This helps me determine what converter is best for his application. When you are looking to buy a converter, please consider the application. My Challenger for example, cruising down the highway at 70MPH, has the engine turning over only at about 2800 rpm, therefore, if I do a lot of highway/street driving, a converter with a stall speed over that rpm would be a poor choice.
If anyone on this board needs a recommendation or my help in choosing a converter (and I don't care what brand) drop me a note. What I'll want from you is, engine size, transmission type, rear axle ratio, rear tire size, cam specifications, horsepower/torque figures, car weight, and what you are going to mainly use your Challenger for.
Cheers
Graham
Transman