1. The larger a country is the more likely they accept a culture or religion because the larger the territory is, the less chance for the collosion of different culture and religion. In addition, it's already impossible for large countries to make a foreign culture an accepted culture. So I don't agree with the tolerance to ture faith and accepted culture thresh hold penalty you propose.
2. I don't know what do u mean by provincial stability. If you mean cost of boosting stability, that would make some sense. But if you mean provincial unrest, I would explain it later.
3. The larger a country, the easier to annex a country of a certain size. For example, if modern China annexed Taiwan, China would just get a little bit of regional trouble. However, if Taiwan annexed China (of course it's unlikely to happen), they would get into a super trouble with managing the conquered territory. Though I don't really understand what do you mean by "cost to conquer", it doesn't sound like a good idea.
4. Although larger country is a threat, it might be a common choice to diplomatically stay close to these super forces. There could be some impact on diplomacy but not simply a penalty. There should be a bonus in some cases.
5. I think u mean provincial unrest by saying "revult risk". (revolt risk is a value from HOI3.)
About provincial unrest
I agree to add provincial unrest but I think there is another way to make it more realistic. I suggest to add a value, "administration range", to each country. This value is influenced by administration technology, minister traits, and something else. There is no unrest penalty for provinces whose distance to the capital is within the "administration range". There is 1 extra unrest penalty for provinces whose distance to the capital is within 2 times of the "administration range" but beyond the "administration range". And so on.
2. I don't know what do u mean by provincial stability. If you mean cost of boosting stability, that would make some sense. But if you mean provincial unrest, I would explain it later.
3. The larger a country, the easier to annex a country of a certain size. For example, if modern China annexed Taiwan, China would just get a little bit of regional trouble. However, if Taiwan annexed China (of course it's unlikely to happen), they would get into a super trouble with managing the conquered territory. Though I don't really understand what do you mean by "cost to conquer", it doesn't sound like a good idea.
4. Although larger country is a threat, it might be a common choice to diplomatically stay close to these super forces. There could be some impact on diplomacy but not simply a penalty. There should be a bonus in some cases.
5. I think u mean provincial unrest by saying "revult risk". (revolt risk is a value from HOI3.)
About provincial unrest
I agree to add provincial unrest but I think there is another way to make it more realistic. I suggest to add a value, "administration range", to each country. This value is influenced by administration technology, minister traits, and something else. There is no unrest penalty for provinces whose distance to the capital is within the "administration range". There is 1 extra unrest penalty for provinces whose distance to the capital is within 2 times of the "administration range" but beyond the "administration range". And so on.