Still same results after calibrating ESCs. Maybe it's normal to have to adjust the min output that much? Still a new to all this, thanks for all the help!
Nope - that doesn't sound normal at all. If you can post your OTX file from the Taranis I can take a look and see if anything looks weird in the setup.
In the meantime, here's a few other ideas for troubleshooting...
Hook up only one motor and esc and with a new model in the Taranis see how it responds to a standard 100% throttle mix (no expo or differential or funny business). Use the channel read out screen to see what channel value causes the motor to start turning. Then keep the same taranis model and connect the other motor and esc and see if it starts turning at the same channel value. If they are different, try calibrating each ESC / motor combo one at a time and see if they start acting the same.
If at the end of those steps the esc/motor pairs act the same we know the problem is in the radio differential mixing. If the esc/motor pairs don't act the same when tested individually with a plain Taranis setup, then the weirdness is somewhere in the BLHeli firware or something physically different about the hardware.