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Technically, the first ounce would start causing damage. The two issues would be 'burning up' the inside of the catalytic converter and clogging the O2 sensor(s). The rate of 'deterioration' would be variable based on obvious factors such as mix ratio of leaded to unleaded, operating conditions, how often it was done, etc.

Typically, at full strength, O2 sensors will last 300-400 miles before they become completely clogged from running leaded fuel at full strength. Catalytic converters, I don't know as you would have to be constantly testing it to see when it was completely gone. Some folks just consider replacing O2 sensors as the cost of doing business and have either put a bypass in place of the cat or let the cat get burned up, as they don't have to worry about emission testing where they live. Others have overidden the signal from the sensors or disconnected them and put in a fixed fuel curve.

One other thing, since I sell the stuff, I have to point out, it is illegal to run leaded fuel in a vehicle run on public roads(includes parking lots).

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Q: How much leaded racing fuel can you use in an unleaded engine and not cause damage?
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