Once my '06 factory JCW is out of warranty, I might want to kick up the horsepower and torque some w/out taking any major chances of breakdown or mechanical failure. Anyone done this, and if so, how?

 

Depending what you consider major... I've replaced my air filter with ITG,Samco inlet hose, factory JCW header and a RMW tune giving me 196hp at wheels vs 178hp stock. Planning on adding Jan's RMW cam to get em over the 200hp mark! I too am currently on warranty.

Davisflyer has the RMW header with the RMW Cam & Tune and now has 223WHP!

 

This is really off topic, but how long is the warranty on Mini's? I'm kind of in the same boat.

 

4 years, 50,000 miles... whichever comes first.

The maintenance plan is only 3 years, 36,000 miles though - unless you buy the extended maintenance.

 

RMW Head, Race Cam, Methanol System, Race Header/Quiet Exhaust, Tune
And a 17% Pulley

Results in the sig.