Hey buddy, kinda gay to here you not having the best of luck. However I do think your barking up the wrong tree 100%
The popping is the exhaust not the engine! Take a video of the engine and you will see its not a mis fire and not misfiring, if it was it would be very juddery through rev range. The exhaust has always had a strange pop to it.
Cutting out wise, Terry may be right with the temp sender however these engines also prone to ICV problems. Take it off and clean the crap out of it with brake fluid/petrol/injection cleaner etc etc to remove the carbon and dirt build up and refit.
Also the down pipe does still has a Lamba sensor on, it would be stupid to remove that. Sorry to here your not happy with the decat...but don't see how its a bodge, its a standard downpipe with cat cut out and pipe fully welded in its place.

Is the smell of fuel burnt or unburnt? You need the sensors plugged in to make sure she aint over fuelling. hope you sort it.