Greg, I agree completely. My 02 Subaru Outback 2.5L engine did the same thing. I cut with the large bit directly against the plate , this is a cable drive TB. So the power increase was right as soon as the throttle opened. This made shifting the 5 spd. difficult and tweaky. I often had to rev it past I otherwise would have, to avoid stalling it, if I instead tried to keep the throttle "before" the Groove. This was worst when going into Reverse.
So I removed the TB and filled the Groove in w/ JB. I'm deciding if I want to re-Groove it, or get another TB and redo it. Either way, I will use the business card trick to open the plate some, likely a tad more than the business card thickness. The total power/torque increase will be less, I think--but this will maintain driveability. Besides, I think having the power boost occur further in throttle angle % will be more useful in urban and hiway driving.
Grooving w/ fully closed plate, is the Basic method of Grooving, it's just that as Ron taught us, The GM DBW TB's need the business card trick EVERY time. Other vehicles/engines/TB's--it depends.
and, Greg, you're right- just a millimeter, or a few degrees in plate angle, can be a night/day difference!
Tracy G