Interesting thread with some familiar faces!
Just thought I'd clear a couple of things up. Someone mentioned every engine is different so you'll need a custom map to get the most out of it.
On a completely bog standard car straight out of the factory car this isn't completely true, a well developed generic map will be far better than a quickly written potentially poor custom map, as engines have come along way since the days of Mini A series units and engines tolerances are very tight, also modern systems have many sensors which closely monitor and adjust all systems in relation to what is happening in real-time, this removes even the minor differences in tolerances, systems like this have been developed so that your car will adapt to wear over the years and still remain within the now tight emissions laws, they do indeed self tune themselves to an extent.
A question, when mentioned that knock was listened too using some sort of headphone, wouldn't it have been a lot more accurate to log the knock sensors over all the runs the car ran? It would be a lot more accurate that way.
I may have missed it in this thread but what fuel was used in the original car in question, also as the ECU was removed after the first power test then the adaptive settings may have been restored so sometimes just disconnecting the ECU will reset these and see a slight power gain anyway, one to think about.
Also a point to note is that fuel quality varies drastically from country to country dependant on the requirements of local emission laws, this will effect output and also is another factor on the standard output of your car, the manufacturer will allow that sometimes you will go on holiday to a foreign country and use fuel of a lower quality and not expect your car to blow up! This has to be allowed for as well as poor maintenance.
Some people ask how can you gain 15bhp with just a chip? well that's sometimes very easy, more often than not car manufacturers detune engine output to fit in with either market placement in relation to other models within there range or more frequently to fit within tax bands, these vary globally so are normally governed by their target market.