Can't help with the first lot but as for the BD chip & intercooler, it really should be OK, the surge could be a dirty air filter or faulty MAF sensor, ring B Davis and tell the problem, he should be able to help.
The flat spot is something i had when i had my air filter box modified and the chip was upgraded to the chip that goes in when the intercooler upgrade is done, it made the down low power woefull, it had nothing from idle to 2000rpm then it took off, i had it changed back to the old chip and the old air box refitted, and it is fine now.
Again speak to B Davis he is upgrading his chips all the time, so there could be a newer one to solve this.
Baz.
Cheers Baz.
2011 Discovery 4 SE 2.7L
1990 Perentie FFR EX Aust Army
1967 Series IIa 109 (Farm Truck)
2007 BMW R1200GS
1979 BMW R80/7
1983 BMW R100TIC Ex ACT Police
1994 Yamaha XT225 Serow
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