Yesterday I reran the Roush throttle body calibration process one more time and this time everything converged quickly. [It may be iterative and need 3 or 4 times to actually get full convergence although they don't say that.] Part of this process is to set idle at 1000RPM.
So yesterday I spoke with the emissions exception gods at the State of Colorado and he suggestedsetting the idle from 1000RPM to as close to but below the limit of 1350RPM. I chose 1250-1300 from the software (not the mechanical tach).
Guess what! It Passed!
The tech guy at the state said that this is pretty close to perfect and that any tweeks I do will now be in the 10% range but not 1/2 again. So I'm done. I may still take it to a tuner for a final "tune" but the basic mechanical and electrical problems that came with engine have been overcome.
This software has a "real time dynamic tune" wizard and I may run it just to see what it does. Like any tuner it's easy to put stuff back.
Now I have to get the VIN inspection repeated because the officer didn't fill it out correctly (they told me what he should put in the boxes), and I have to get it weighed. Plate SPRSNAK is waiting...
Sales tax hurts...