I just cannot think of an easier way to go ... low restriction exhaust and intake (TOR's and Triples), PCIII (or V) for fuel mangement, remove the secondaries (to take away computer control) and a GiPro (or resistor mod) to manage the built in timing restriction. By just doing this and using the PCIII's D&D-secondaries-triple K&N tune, it was done (you can download that off the web site). The place I ordered the PCIII from put the tune on it for free before they shipped it. So all I had to do was plug it in and done. My paranoia alone forced me to have it looked at and dyno-tuned, the minor tweeks the tech performed at that time were not necessary. I gained a couple ponies by having it done, but it wasn't worth the cost (it could have just been scratches on paper to justify the $250). The numbers that were altered in the tune were miniscule. It ran and would have been just fine without ever involving the dealer.
T, I'm sorry you are so far into it now, I feel your frustration ... at this point you have no choice but to continue trying to load something in order to make it run. Keep after those guys at TuneBoy, they certainly owe you something (like a running motorbike). I'm sure it will work out before summer. Good luck to you.