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I don't understand why you're having so much trouble with a non-turbo set-up...?
The "mistakes" you mention are all basically rookie mistakes that could've been easily prevented if you have made diligent checks.
Blaming stuff like "spark plug boss growth" is almost - I'm sorry to say - BDC-esque, where you're grasping at straws looking for something to blame...
Tuning the NA should be pretty quick and efficient.
Messing around with spark plug heat ranges shouldn't be that big of a deal unless you're tuning on the ragged edge of reliability?
(I thought this was a daily driver?)
The fact that you're fighting "dirty" spark plugs implies that you're still running too rich, or your spark plug heat ranges are wrong - i.e. too cold.
What's going on?
-Ted
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