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The other thing that won't cost a whole lot is to install a smaller and/or lighter flexplate. This will help acceleration a little but i'm not sure it's effect on mpg.
Good point. Alright, forget about the lighter/smaller diameter flexplate for now. i need to do more research on this concept.1) i've been doing some reading and it seems that people switching from the crank-driven fan to an electric report more power and better mpg:http://www.67-72chevytrucks.com/vboard/showthread.php?t=286800http://www.youtube.com/watch?v=9OQtVUh1VWkNOTE: for the video, i was looking for something else and stumbled upon that. Just as well.Other things which don't cost a whole lot while raising power and mpg may be:2) Use synthetic oil. And possibly 5w-30 instead for less resistance. i know a small block should take at least 40 weight but.....Also, run 1 quart low---less drag.3)If you can change it out yourself, then possibly lowering the diff gear may help performance and possibly mpg. But be conservative----i.e., 2.56/2.73 to 3.08.4)jack the front tire pressures to 40 psi, possibly higher. This may not be good for the tire, but you asked for performance and mpg without spending money which is asking alot.5)really nitrous is probably the only real solution based on the parameters you've provided.6)Fiberglass. Not cheap, but in context it is.7)Roller lifters and rockers.With all the above, the dollar outlay is not real large and the gains are not too large either.Really, with a 73-91 truck, the only way to get performance AND mpg is to spend at least 2K. (but really more than that.)Sorry kid. But at least you've got a decent, dependable truck that is cheap to maintain.