I feel your pain with results never being posted!! I tried to answer your bullets as well as I could. I answered mine with bullets for ease of reading:
-I love the way my setup is running. I have G4 IM, headers, 2.5" exhaust, and CAI. I will say this mod was my favorite because it didn't give me as big of a headache as headers did and gave just as good gains if not better gains than headers did. Butt dyno = fully satisfied.
- I have Millenia throttle body. You do have to file down the bottom side of the flange on either the IM or TB, but you seem to know that already. Don't let that worry you though, if you buy both it'll make sense when you physically see them butted against each other. There are some threads of guys using KLZE TB but it seems much more difficult than its worth with really no gain to be had iirc.
- I still have the stock MAF. I'm sure gains would be had with going VAF, but minimal unless your boosted (someone correct me if i'm wrong).
- Hood clearance is golden.
-I used the Spectre tubes you can buy from Autozone, Advance Auto, PepBoys, etc. You can make the filter sit whatever way you want and i love the placement of mine. Idk how an ebay CAI would sit, but it may work.
-- I will say do your research when connecting the vacuum lines. They're a PITA if you don't do it right the first time. I have diagrams of the KLDE vacuum diagram and KLG4 vacuum diagram if you need both. The TB gasket you use with this mod is the KLG4 TB gasket. Part # is KLG4-13-655. The stock IM gasket is fine.
93 LS-DE- Hotshot CAI, G4 IM, KL47 TB, HEI+MSD, SSAC Headers, EGR Delete, high flow cat, Magnaflow, Weapon R coilovers, Meganracing STS, Smoked Tails, Pioneer 4 ways, Soundstream amps, Kicker CVX 15, custom box.