you should be able to do away with the ecu, IIRC they use an edis/esc system which can run standalone, although not as good as a fully mappable setup.
twin 45's will really be needed, 40's just won't cut it up at that power.
as for egr, it shouldn't strangle performance is it closes the valve when giving it some and only come on at cruise to maintain economy and reduce emissions.
you can just blank it off though, or make sure the valve is just closed.

also to get the power up 10-20bhp over standard shouldn't cost much at all, upto 170bhp should be pretty straight forward, nice exhaust filter and a good setup should get you to that.
cams to pull you upwards, but then you'd need to start looking at higher comrpession etc.
probably cheaper to fit a zetec engine, where parts are going to be cheaper to find.