Can you post picture of all 4 spark plugs and take note of which cylinder each plug is from, It is unfortunate that a proper analysis was not carried out when a piston broke on first engine, could have saved all this hassle with having to replace a 2nd engine and now subsequently a 3rd engine.
I have mapped a couple of Euro R Accords 2003/2004 the wiring is probably similar in which case you can run a Hondata Kpro ecu along side standard ecu with a specially made harness. Let me know if you need a contact to purchase ecu and harness from.
3" catback on the k20 engine's are worthwhile. The Skunk2 catbacks are very good and the 76mm would be ideal for your engine. Just be warned though they are really loud!
@ Wayne & Dotty
Noticed neither of your dyno sheet's are displaying "shootout mode" not sure why your tuner hasn't put the dyno in shootout mode??? When the dyno is not in "shootout mode" rotating inertia and ramp rates are not locked out so they can be altered by the operator to let's say...
It can be a number of things some times related to a wiring issue, cam sensor, VTC oil control solenoid and even in some cases it has been reported a fault within ecu.
The VSS been off is due to the mph converter.