... I think the max peak g1 signal is ...
Maximum G1 input before distortion is solely about how you have the tube biased. So if it distorted with inputs greater than 16v, you had maybe 17v of bias or less.
... The last kt I built was at the datasheet typ class a, about 400 plate, 84ma idle but I could only drive the g1 to about 16vp-p before the tube started distorting the output. ...
A KT88 is rated for 42w, and class A amps are typically biased to 100% dissipation at idle (you could idle cooler, but you just get less power output). 42w / 400v = 105mA
Had you idled the tube hotter, you would have used an even smaller bias voltage than you did, so distortion would have began with a smaller signal.
That sounds like a problem, but you'd also be
getting more power output with less driving voltage so really your amp would have had better performance. I dunno why 16v peak is a magic number, because if you're getting distortion you simply turn down the volume and apply less signal.
My thought process is to develop the largest ac I can without distortion in the PA stage. I was thinking the "bigger" the plate volts, the "bigger" signal I can produce without clipping.
Remember voltage is NOT the only way to power. High-current makes power too.
You listen to a speaker. The speaker is a low-impedance coil of wire in a magnetic field; current is what moves it.
If you have 40w applied to an 8Ω speaker, then √(40w*8Ω) = 17.9v is across the speaker impedance. If you have 500-600v of signal swing at your tube plate, the output transformer still has to step it down to ~18v to deliver that 40w. The bigger the voltage step-down ratio, the more likely you will run into limitations in your transformer.
17.9v / 8Ω = 2.24A
Power = voltage * current
~40w = 17.9v * 2.24A (some rounding error)
If you have an 800v supply in your amp to allow the KT88 to have a ~510v RMS signal swing, then 40w / 510v = 78mA of current swing. High voltage times small current or small voltage times big current. Either way delivers the same power.
And distortion isn't predicted by deciding high or low supply voltage (loading changes everything).