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"I'm starting to suspect the BPV wasn't calibrated correctly. OR somethings pulling way too much vacuum on it, cause it opens at startup and basically stays wide open"
This is normal behavior. Vacuum at idle is (or should be) more than enough to pull the valve fully open and hold it there, allowing uncompressed air to bypass the SC rotors.
When my valves diaphragm had a tear in it, there was still enough vacuum to open it and hold it open at idle so the valve appeared to behave normally. However, due to that tear, I now had a vacuum leak which gave me the same symptoms you're seeing right now.
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