The drivers side Intake cam broke. Cosworth 278/274 AVCS cams with 4k miles. There was no other damage to the engine! Wear on the cam buckets, lobes, and bearings looked normal. There was no "smoking gun" besides the broken cam. And there was no indication of a build problem or a tune problem.
Cosworth replaced all 4 cams, no questions asked. The timing belt and tensioner were replaced. The lower uppipe gasket was totally destroyed! Also replaced.
Needless to say, I have my car back after a little over a month of downtime, and about half the time we were waiting for the cams to come back.
I fixed most of the drivability issues in a 10 minute tuning session - the ECU fuel map is really sensitive at low rpms and things were off just a bit. I ran it up to 15psi... the car feels great and sounds absolutely nutty. I datalogged both the ECU and the UTEC and everything looks good. More boost tomorrow
Thanks to Synapse for getting my car in and out of the shop so quickly! I think I might sleep in my car tonight.