It's never too late for an OCC. Your just preventing more carbon buildup. I love to do a full cleaning service with walnut blasting AND catch can install, especially if you are doing the crank case vent on the block, it makes it that much easier to do the install. Plus you have a clean start and slow down the process of getting dirty again.
Yes... for the walnut blasting I bring the cylinder to TDC so that the valves are closed and then blast and vacuum and make sure all the pieces are out of the port. It gets really messy but its all worth it. I end up having to air blast the car and my whole shop and still see the pieces of walnut everywhere.
That being said, the reason we use walnut media is because it is combustible so it will burn up. My only concern is the pieces going through the turbo. The cat would burn the stuff up before it clogs.
I usually charge removal and replacement of intake manifold plus 1-2 hours of blasting. (R+R of intake manifold on fiesta is 3.0 hours). I like to replace the intake manifold gaskets while I am in there, especially on higher mileage cars. The Mazdaspeed has a metal gasket that only likes to be used once but the ecoboosts and bmws have rubber that can be reused, but for 10-20 bucks you might as well. So, $400-500?
I have the walnut blasting tool for the n54/55 and its AWESOME. Makes the whole process super clean and I don't get carbon blasted back onto my face, which is nice. I have plans to design and CNC a similar tool for the mazdaspeeds and I would be willing to do so for the fiesta and focus if there was enough interest.
I disassembled a 2.3 ecoboost with only 300 miles on it and already saw oil on the back of the valves. However, those were the hardest 300 miles any car should ever see, aka about 100 quarter mile drag runs, so it may not be the best comparison.
Here are before and afters from a 80k mile N54