I don't think it is reliable to say that the end result (SO/HO) would be the same. I'm not saying it won't ever be close to being true in any example, I'm saying its not reliable to make that broad of an assumption. It's an interesting way to look at it, but typically the box crowd (as I have interpreted it anyway) prefers to view things in terms of "how much improvement will I feel". raw, absolute numbers are not as meaningful to some because you have to do some additional work to understand how *your* truck will be affected. And most guys (again, my take here) like to know what the box will do to *their* otherwise stock truck.
As regards the ability of the mechanical system to make power, I really don't know how different the HO and the Cali SO motor are. If memory serves the piston and head designs are different, motivated by differnet objectives (NOx for the 235 versus HP for the 305 engine). They're certainly different animals -- a 30% increase in stock power is substantial, and the way ECM programming accomplishes emissions conformance is also different. Unless I'm mistaken, the 235 HP Cali engine has differnet combustion parameters that will respond differently to the various fueling boxes. As you will see below, none of the fueling boxes out there (with VA as the only exception) replace bits.
With one exception, today's boxes for the HPCR all work in the ANALOG DOMAIN. thats right. they acheive their power gains by introducing error into the analog signals that the ECM normally sees, without touching any ECM bits. Manifold pressure information and fuel pressure information are analog (continuously varying) voltages. make no mistake, these methods are effective, but they don't simply replace stock bits with higher powered bits. In fact, no ECM bits are ever changed -- the ECM itself is left to control everything the way it was intended to. In fact, the ECM thinks it is operating stock.
Consider that ECM programing is vastly different between the 235 and the 305 engines becaue the programmers had different objectives. The only thing a fueling box does is give the ECM different manifold pressure and fuel pressure voltages, and the rest is up to the ECM.
Now then, The Banks box is a "pressure port" fueling box with the addition of analog timing. thats right, the signal coming off the crank is analog in nature (it is a pulse stream, not a binary number) . Here again the ECM program itself is untouched and unmodified. Timing advance is accomplished by inserting delay (error) into the pulse stream coming off of the crank sensor, for example, so that the ECM will compensate by advancing timing. none of this ECM fooling is in the digital domain. no bits are changed directly. the ECM itself remains in full control according to its OEM programming.
with regards to my Banks statement, there are the following concerns:
1. taking the CAT off is illegal. unless I read the Banks site incorrectly, the Cali 235 engine making the published HP gains on the 235 HP engine had no CAT. I'm not saying no one will do this, but for me personally I wouldn't. Especially for the crowd to which Banks appeals (protect the power train, mild performance gains, etc. ) I thought that CAT removal was a stretch.
2. With Banks exhaust (undoubtedly including their very nice 4" downpipe which removes the stock 3. 5" restriction at the turbo), Banks muffler, the wastegate modification, AND a new intake system, you have substantial modifications, amounting to a purchase cost well in excess of the box itself. You have to pay some big $$ in ADDITION to the the cost of the box in order to see the performance gains posted. And when you're done, your truck will be illegal to run on the street.
California guys, please correct me if I'm wrong. Is it legal to remove the CAT?