Not to derail the detail but…I like your style but you might be a tad optimistic on 20 mpg with an 8.1. Best I’ve achieved is 16mpg on a couple of trips. Granted that’s with a heavy pig at 7400ish pounds and the aerodynamic equivalent of a drive in movie screen. I think there’s some room for improvement but not on my truck in its current form.I agree and I went from a gmt400 1500 with a 5.7 getting 10 mpg to a gmt400 2500 with the 7.4 getting 12 mpg.
I am hoping my other square with the 2003 8.1 I am putting in with an nv4500, gets more like 18-20 mpg based on what the guys here are getting with a little tweaking of the ecm.
Get the weight down is critical. Not running a camper would greatly improve the aero for sure. Gearing and tire size will net some results too. With the nv4500, 4.10 gears and 315/75r16 tires at roughly 34.6 diameter nets just under 2100rpm at 70mph. The 4.10’s give up a little grunt down low but the 8.1 makes it so you wouldn’t notice it. Not sure of your end plans for the truck but depending on on what they are target for 2000-2100 rpm at your ideal highway cruising speed. That keeps the engine in the meat of the torque curve and limits most needs to downshift to pick up speed to pass or climb grades in fifth.
I think 18ish mpg is attainable with an 8.1 it’s going to be a challenge that’s not all in the tune. Back in my workhorse days we had a dealer in California selling “tuned” pcms for 8.1 equipped rv’s. Made some bold promises like they all do , more power and better fuel economy. It’s been a while but I want to say they claimed up to 10% better fuel economy on th tune alone. On a 22k pound gvw class a rv getting 6-8 mpg that’s a bold clam.
Those of us at the company had our suspicions what they did to achieve this by leaning out the overall fuel table. Our suspicion was validated when a rv with a bright red pcm with the shops name on it came into another dealer with a blown 8.1. Teardown found multiple pistons with holes in it. A pretty clear case of going too lean and elevating combustion temps to the point of melting pistons. Warranty claim denied obviously and the tuner shop who also happened to be a servicing workhorse dealer reached out to bitch on behalf of the customer that we denied th repair. It was a pretty short conversation with a reminder that his tune was not factory nor validated to the level GM normally did to avoid this. Moral of the story being don’t lean that tune out for fuel economy so far that it will burn up under a moderate load.
Tech derail complete, you can go back to the regularly scheduled wedding planning content.


