40K Mile Update
I hit 190K miles today. It's been 40K miles and almost exactly 2 years since I started this build.
I think I've done just about everything at this point. Autocross, dragstrip, mountain roads, deep snow, 1100+ miles in a single day on multi thousand mile road trip, lumber runs from Lowes, and more.
The car's been pretty reliable, most problems has been sorted out, and the car isn't too quirky for being a true daily driver. I've had other people drive it on different trips and there's no real learning curve unless they wanna go WOT.
A few remaining issues:
Intercooler condensation - I've had two instances of intercooler condensation causing the car to stumble. Both occurred at heavy throttle after a long drive through heavy rain under light load. I did pull the MAF the second time it happened and the MAF was wet with water droplets. I think I just need to either avoid heavy throttle after driving through heavy rain, or just go WOT once in a while to prevent condensation build up in the first place.
Fueling - There's two issues associated with fueling. First, the car running leaner in the cold and richer in the warm. This is simply a limitation of the platform as there is no IAT fueling compensation option in Ktuner. I suppose you can run two different tunes, one for the winter and one for the summer. This brings me to the second issue. I've had some problems with the car maintain fuel pressure at WOT. I did a bandaid fix by simply upping the base pressure to 65psi instead of 55psi. The fix certainly works, but I can't seem to figure out why this problem is happening in the first place. I'm thinking it might be a dirty fuel filter, or it may also just be that I've maxed out the factory returnless fuel system even with the AEM 340 pump.
Cruise control -The only problem with cruise control is that the RES function freaks the car out if you press it at a speed that is significantly lower than the set speed. The car goes on and off throttles continuously as the car is accelerating significantly faster than the computer anticipated. I once tried to accelerate to HWY speed in D3 using cruise control and I think I broke my neck as the car kept on rolling on and off throttle.
At the current state, the car really has no torque down low. Which IMHO is a good thing. It discourages you from driving too fast in a daily situation, reduces wear to motor mounts, tires, and axles in stop and go driving, easier to drive in the snow, and smoother start. At the same time, the car can still muster up enough boost and torque during highway cruising to never need to let TCC go in 5th. I was also told recently that the turbo lag is very noticeable from the outside as well. The last time we went hiking, my friend with a Focus ST told me that he can tell when my turbo really spools as one second he's keeping up and the next I'm pulling away from him without any signs of a gear change.