K&N and beyond....
I intend to test at the track.
The CFM flow number from K&N tech department on the E-2443 application filter (all 4.5L 80-100) is 874 CFM. Have you done the math on the stock 4447Liter motor CFM? As many have said, Mr. T so overbuilt that oem filter that K&N could go even smaller.
What are you testing at the track? Use the gtech, I've used one and gotten within a .1 on the quarter and just about dead nuts on the dyno. For a back to back, that's all you need.
I have heard nothing negative re Bosch Plat IVs. Everything I have read has been positive. I have been running them for 60k miles and have had no problems. The advantage with the Magnecors is also longevity rather than raw performance gains.
Plat IV's use a ceramic coated electrode, not a ceramic electrode (like the FD5POR for example). It also uses a little tip of Platinum vs almost .200in of it on the F5. What I find happens with the cheap ones, is that the ceramic coating cracks, then the spark travels up the side of the electrode, negating anything close to a better spark. Again, the stockers are fine, you won't blow out the spark using them, so no gain is had from a 2.99 plug. In fact, since bosch is the oe for the turbo audis, I go thru this all the time. I recommend either FD5POR or just use the triple coppers (xxxDTC), they are the same price as the PIV and are a much better plug design. Regarding wires, the stock wires last forever, I replaced mine as PM at 12 years, well, because. That indicates to me that the new stockers will last another forever.
I could see 2 3" inch cats if you plumbed them side by side (not sure how that would be accomplished) possibly increasing flow but I can't see it if they are consecutive. That isn't logical. You are increasing the amount of media through which the exhaust must flow. That would be like saying that putting two mufflers in consecutively will increase flow or eliminating your cats altogether would decrease flow
I speak to leaving a cat for each bank, not in series, yes in parallel. It's easy to put dual high flow cats on the 80, cuz it already had them from the factory. In terms of the honeycomb, it's really tough to claim that laiminar flow thru a grid less than half the size of 2 grids will yield better flow. Even if you account for velocity. Exhaust is all about pressure drop. I doubt a 3 in system with the stock cats would decrease flow, and can math out that a 3in honeycomb cat will cause a higher restriction than the stockers. I also suspect if you took a measure of pressure drop on a cat back 3in, the 3in muffler would yield the highest backpressure, not the stock cats. BTMT on a lot of cars in my shop.
The more tricks you make your exhaust do the more restriction you create.
Not necessarily, x pipes, crossover pipes, antireversion steps, catalysts, nozzle diverters, laminar flow converters, all are tricks that give performance and flow gains, and can add no additional restriction.
Chammfered holes. The pads are actually ferro-carbon heavy duty. I was running through oem brakepads every 15-20k miles. I have had these suckers on there for about 40k with lots to go.
Glad you think it's working for you. As a rule slotted rotors tend to eat pads quicker, because the edge of the slot will clip them. I suspect that the carbon pads did more than anything to the rotor. Cross drilled look cool, I suppose, but there is little to support cross drilling or slotting that will yield gains in the 80. Put SS lines on them, and get air to them, run the stock pads. What gets the 80 in trouble is heat, btdt at Steamboat. A cast iron caliper needs to dissipate heat, pads don't do that well. Carbon can take more before failure, but they tend to be less agressive on initial bite, then get more so as they heat up. The problem with them IME, is that you overheat them, they will eat rotors immediately. The Semimetallics will get soft, indicating you have some heat issues before they eat the rotors.
Again, I only look at what you've done vs what 'gains' are inherent to what you've done. It's your machine, I only encourage testing in some quantitative manner. In the case of the K&N, you don't even need to test, just calculate... You are wasting your money if the stock paper filter flows half the CFM.
ST