Ive been following this thread since its inception. The problem I see is that when you start looking for hp on a computer controlled engine, changing one paramater will always affect many or all other paramaters.
MSP, I commend you for the work on your dual setup, but the shop didnt use mandrel bends on thier work. I question if your exhaust flows or has the ability to flow any better than the stock setup. It will only flow as much as the smallest restriction. Thats why an engineered system from a reputable company will almost always outperform some "hachet job" a local muffler shop can put together.
Generally, when doing mods the rule of thumb has always been to work from the tailpipe foreward. I think most people modding the V6 will be satisifed with intake, exhaust, tuning. Just those basic mods will run somewhere in the neighborhood of $1000-1300. Thats a pretty big cash outlay for a gain of maybe 20hp at the wheels.
Im also not convinced that the CAI's currently being offered are of much benefit. My previous car was a 03 Focus ZX3. The 2.0 zetec was rated at 130hp. The 2.0 SVT Focus was rated at 170hp. Both engines used the same air filter, the difference being that the SVT had a larger intake tube going into the airbox, and a larger MAF. I think our airbox flows plenty for the 4.0 and the better gains would be an improved tube from the airbox to the TB.
My only mod so far is GT rims/tires. If I can I will dyno my car stock. The only mods I plan are 3.73 gears, T-lok, exhaust, tune.
Im useing the 3.73's because I already have the gears, Im only going with a tune because I need the speedo calibration. Im keeping my car on regular gas. If someone comes up with a better intake tube I will replace that, but I dont care for a CAI.