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And then a miracle happened!
When it came back from Roush they said it worked at their location. This left the altitude and some other differences. So I tracked down an Accel EMIC in Ft. Collins, described the problems I was seeing, and sent them some data logs. They confirmed that the issues were probably altitude related and I brought it up to them.
Today I got it back. We did as spirited a drive as we could up to Cameron pass (10K+ ft), I put it through the spirited acceleration test several times along the way, and it works flawlessly! Wow, what a difference.
The major changes were done to the altitude table from 5000+ up, with a few low RPM changes to the base VE table.
Now it runs like a BOH.
Now we're not sure what it will do going up to from lower altitude to the 5000' region. It's hard to take it down in altitude but I may take it to Vegas in September. They said they can blend the two tables and that the stuff he did from 5000 to 10000 was pretty linear so it shouldn't be too hard to interpolate.
Kudos to Garry and Jordan at Lundstedt Automotive in Ft. Collins.
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