I actually wrote some Python code to help answer this exact question! =) It simulates a bunch of ascents and reports the attributes of the best one. http://www.reddit.com/r/KerbalSpaceProgram/comments/1tavqb/finding_the_best_ascent_profiles_with_a_script/ One thing the script taught me is that limiting your acceleration (to a fixed number, not just to terminal velocity) can help. If you achieve a high apoapsis too soon, you miss out on the benefits of a slow and steady horizontal climb and end up spending a lot of delta-V to circularize. You can run the script for yourself, but I'll go ahead and tell you that your gravity turn is ending too high. Assuming your ship has a drag coefficient of 0.2 (MechJeb can show you this), try limiting acceleration to 2.2 g's (21.6 m/s) and using a turn from 8.12 to 45.64 km, with a shape of 57.1%. (Your final flight path angle should always be 0 degrees.) My script says this'll result in a delta-V of around 4399.76 m/s (with losses of 1415.29, 902.19, and 44.14 m/s to gravity, drag, and steering) to get to a 100 km orbit. (Note: My script also assumes you have MechJeb's "corrective steering" setting -off-, though it doesn't make a huge difference.)