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I wonder if you can figure out the ignition timing vs. valve timing per RPM to see where the piston is relative to the firing.
Seems to me, the best mileage is when you are getting optimal bang to push the pistons down. Taking into account the flame travel time and engine timing (piston, valve timing, and ignition timing), it would seem that would work out to be the best for emissions. I am surprised you can smell the difference. Is it a (unburned) gas smell?
If so, that would not be good for the cat as you could burn it out early - then the mileage would drop and codes tripped...
Jerry
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