Welp, that didn't last long. I know what my next project is going to be <sigh>
Apparently the noise I though was the oil cooler knocking wasn't... engine. Guess you can add me to the list and send a Nelson ha-ha my way.
Engine autopsy will have to wait a bit until I can pull it. Leaking oil from passenger side but haven't been able to get under car to inspect it yet. Will do so in the next few days, need to mod my jack stands a bit.
Sounded like this pretty much the entire way home -horrible clatter. I did manage to limp it home; wasn't sure it would make it a few times -it definitely got worse as I went, but honesty I figured the engine was toast based on the behavior right before the big noise, so I wasn't really worried about saving it. I though the noise was from the drivers side heads, but the oil leak is on the passenger side.
Other info:
Engine was acting unhappy during test drive. I had run it up to 70ish and about 10 PSI boost. The oil temperature started rising from 190 to 220 (oil cooler and fan were running at this time). Was sluggish until about 4.5K, then it seemed to spool up quick, was thinking turbo/WG problem. I did hear a significant amount of wastegate flutter during one hard pull, but that's the way this turbo/internal WG had been on the dyno runs.
The CEL light was from missing evaporative controls & missing TGV's which was known since I'd removed them during the install. I need to check if there are any new CEL codes.