In order to explore the potential of the K04, a corresponding tune (like GIAC PC16; what similar alternatives are out there?), it looks like I need larger injectors (317cc from the TT180, 3 bar fuel pressure regulator) and front mounted intercooler?

What FMIC will do the job? I hate the idea (plumbing hazzle) in the first place, and want to get the most cooling capacity with the least amount of work/money.

What is being used? Is 22x5.5x2.5 (2.25" air connection) bar/plate sufficient?
Or do I need as big as 25x12x3.25 (3.00" air connection)?
Are Speed Daddy and similar inexpensive once at least usable?

Any good FMIC built instructions out there?
How much are complete aftermarket FMIC kits (if they exist)?

 

There are different companies that offer complete set of FMIC. APR being one of them and also Evolution Racewerks. These complete kids would run somewhere around $1,000+ depending on what you get/what custom work you want.

There's also the DIY "cost effective" way: https://www.audiforums.com/forum/sho...t=45643#382435

 

Many companies offer an FMIC for the B5.

APR
Racetec
ER
Kinetic
Forge

But really, if you're still hesitant on injectors, piping and such you're better off saving hundreds and just getting a core off ebay. Piping is your choice. I would do 2.25 for a K04.

 

At this time your best option would be a Racetec FMIC, it fits behind the stock bumper where as the ER and APR do not. It is also the perfect size for a K04.

You do not want to go too big of a core, all that will do is cause the turbo to work harder and you will get more boost lag since it will take the K04 longer to fill up the core and decreases velocity of the air flow. You also want to stick with 2" pipes, dont go any larger then 2.25". Even those sizes are good for up to a GT30, no need for 2.5" pipes till you are pushing a GT30r really hard or running a GT35r. If the pipe is too big you will decrease air velocity and this will effect the amount of air moved. Bigger pipes are only needed once you max out the size of the pipe and belive me a K04 is not going to max out 2" pipes, the 2.5" pipes can handle enough air to make over 700chp.

When it comes to pipes and cores, larger is not always better.