Jamieson,
I can feel your frustration, all the way in Montana! This is actually frustrating to me as well.
Sorry to be the bearer of bad news, but pumping the intake full of smoke is NOT a vacuum test. A TRUE vacuum test requires applying a vacuum to the system in question. You cannot find leaks under the dash or in the booster (or small ones that make BIG problems) by using a smoke test. I don't care WHAT the glorified parts changers tell you.
The science of it doesn't apply. Period.
I don't know if this will encourage you, but I just got off the phone with Gerrett Herning, Vice Chair for the Minnesota SAE. He wants to test the principles and The Groove on two engines. In discussing capping the PCV, he didn't bat an eye. In fact, he immediately recognized the benefits.
As to the IAC, just open the 1/8" hole to 1/4. I did that and it smoothed out the cold ops. It's turning Winter here, with the first snow on the ground, so I may have to open in a tad more, but as I have a similar setup on my Expedition (which is still 19 MPGs compared to the 9 I started with) you should see similar results.
Anyway, don't let 'stuff' bother you. I get tired of brushing my teeth, and I still get cavities. It's a running battle!
You say you've been at this a whole year. why don't you send me your TB and let me take a look at it? It would be my pleasure to inspect and make recommendations as to your application. Most guys have trouble cutting their first.
How about letting me help?
Oh, and get a Mityvac 8000....
PS: Here's a sample of Mr. Herning's work on the Singh Groove:
http://www.herningg.com/singh/Ionization%20current%20analysis.pdf