hello and congrats on your hard work and perseverance! i have had a similar obsession with the tripple stage vtec myself ever since i read about it a couple years ago at this site:
http://asia.vtec.net/article/d15b/
i noticed you put the vtec-e disengagement at 2500 rpm to keep with where the d15z1 is set. however, according to that article the d15z7 disengages at 3000 rpm. i thought that seemed about right being that that engine is mated to the tranny that has the same gear ratios as EX/Si (and yours) and thus needs a little more rpm to rev. have you tried setting it to 3000 instead? maybe then you could shift right at that point and see increased city driving as well as try to cruise right below 3000 rpm during interstate driving.
a little about myself. i did own a 92 VX but sold it months ago as it had this musty odor when i bought it and i am sensitive to mold, thus i am very picky about owning older cars and cannot handle any car that has been rained and molded. too bad b/c i liked it a lot and its lightness prevailed and even handled very well for a totally stock car with 13" Michelin's.
as a side note, in talking about getting old cars so we can save money and get better gas mileage than newer ones, i think it is worth mentioning i did find out where the water leaks in the back of the EG hatches come from: the window struts getting old and putting more stress on the nut that secures it to the window.
you can get new ones at Advance i think and get nuts from your dealership and have a leak proof hatch once again. too bad no mechanics or honda-tech guys ever told me why they leak but i finally found out b/c i HAD to replace the stripped out nut that broke on that VX soon after i bought it and then low and behold the water puddles ceased.
anyway, i talked to one guy who delivered pizzas and used to have a VX and he missed it greatly, especially as he delivered in his turbo WRX! he said he did get close to the 55 mpg. he also took a power steering wrack from an Integra and gave it ps. i thought if i was ever gonna convert a VX, then a Type R wrack would be awesome since it has the quickest steering ratio--nice wrack!
ok, so i got as low as 39 mpg around town but usually got 42 mpg. my record, on interstate where i kept it right below the vtec diseingagement of 2500 rpm (close to 75 mph), was 45 mpg. i never knew why i couldn't get better than that and if i needed a new O2 sensor or not.
but that brings me to a good question. does the d15z7 use 1 or 2 "LAF" (lean air fuel) sensors? and if they need replaced, what kind is it? is/are it/they identical to VX LAF sensors? if not, is there a supplier that can fetch it from Japan w/o raping us? you gotta understand that i have not known a single person to get this engine and it is hard to find info on it even in the forums. you not only getting one but putting it into an obd1 car makes you a true pioneer and with tuning and all, i have great respect for you.
i had this same idea too but i thought if i get the motor i'd first test it by putting it into an obd2 car, for which it was designed. yes, the 96+ sedans are gonna be 250 lbs or more than a VX, but that's life. after i saw my 93 Si B16 hatch get stolen, i got kinda demoralized about the whole EG h/b thing, despite my former love for them. they just attract too much attention!
so i bought a boring sleeper set: a 95 LX sedan and a 98 DX sedan. the 98 DX is totally stock and i have been getting 36 mpg for the last several fill ups now that warm weather is here and even 37 the last time!
i noticed you have a 37.83 mpg sticker posted. is this about to be updated with a higher #? i may be totally wrong about this but i thought i read that the wide band 02 sensor is more tuned into the lean burn operation, and thus when one is operating their VX above the vtec-e range, they may actually get worse FE in that higher rpm range than a standard non vtec-e d15 (using the same VX tranny) that would still be optimized above the 2500 rpm zone, using a normal 02 sensor. i'd like to see what you got just maintaining a cruise right under 2500 rpms (unless you do move the vtec-e disengagement up to 3000 rpm and keep your cruise below that).
last question i have for you is for the rest of us who aren't brave enough or willing to put your d15z7 into an obd1 car: do you think it is any more difficult to put the d15z7 into a 96-98 Civic DX/LX {requiring the use of the JDM CPU (from a VTi or whatever it comes out of) and running wires for knock sensor and vtec} than it is to put a d15z1 into a civic EG that was non vtec?
thanks